Pack Manufacturing Engineer at Forge Nano in Thornton, CO

Position Summary

Forge Nano is seeking an experienced Pack Manufacturing Engineer to lead the development, implementation, and scale-up of our in-house battery pack manufacturing capabilities. Reporting to the EVP of Energy Storage, this highly hands-on role will serve as the technical manufacturing lead responsible for transforming battery pack designs into safe, repeatable, and scalable production processes.

The Pack Manufacturing Engineer will work directly on the manufacturing floor to establish assembly methods, tooling, fixtures, quality controls, inspection processes, testing protocols, and manufacturing documentation required to support battery pack production. This individual will partner closely with Engineering, Quality, EHS, Program Management, and Manufacturing teams to ensure operational excellence, product quality, and compliance with applicable standards.

In addition to building manufacturing processes, the successful candidate will serve as a mentor and technical leader for battery pack assembly technicians, helping develop workforce capabilities and reinforcing a culture of safety, quality, and continuous improvement. This role is ideal for someone with extensive hands-on battery manufacturing experience who enjoys solving production challenges and developing high-performing teams.

Responsibilities

Battery Pack Manufacturing & Process Development

· Lead the implementation and scale-up of battery pack assembly operations at Forge Nano.

· Translate battery pack designs, specifications, drawings, and bills of material into robust manufacturing processes.

· Develop assembly sequences for battery cells, modules, busbars, wiring harnesses, BMS components, thermal management systems, enclosures, adhesives, insulation materials, fasteners, and related hardware.

· Establish manufacturing methods for fastening, adhesive application, electrical interconnections, welding processes, battery management system integration, pack closure, and final testing.

· Identify, specify, and support procurement of manufacturing equipment, fixtures, tooling, gauges, safety equipment, and test systems.

· Support pilot builds and transition prototype assembly processes into repeatable low-volume production operations.

· Lead manufacturing readiness activities for new battery pack designs and production launches.

Production Operations & Continuous Improvement

· Personally participate in battery pack builds and demonstrate best-practice assembly methods to production personnel.

· Identify potential manufacturing risks and develop mitigation plans before production builds begin.

· Troubleshoot manufacturing issues and drive structured root cause analysis and corrective action activities.

· Participate in Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews, providing practical production-focused feedback to engineering teams.

· Partner with suppliers and external manufacturing partners to transfer battery pack manufacturing knowledge and best practices into Forge Nano operations.

· Convert project objectives into actionable manufacturing plans, schedules, milestones, and deliverables in collaboration with Program and Project Managers.

Quality Systems & Compliance

· Establish in-process inspections, acceptance criteria, traceability requirements, and manufacturing control plans.

· Partner closely with the Quality Management System (QMS) team to develop manufacturing documentation, process controls, and quality standards.

· Support process validation activities, manufacturing readiness reviews, and quality improvement initiatives.

· Ensure manufacturing processes meet internal quality standards and applicable customer, industry, and regulatory requirements.

· Maintain detailed process documentation, work instructions, inspection procedures, and manufacturing records.

Technical Leadership & Team Development

· Serve as the primary technical resource for battery pack assembly technicians.

· Train and mentor technicians on assembly processes, tooling, equipment operation, workmanship standards, inspection requirements, and manufacturing best practices.

· Develop clear, practical, and scalable work instructions that support consistent execution across varying experience levels.

· Provide daily technical guidance and hands-on coaching to support workforce development and operational excellence.

· Help build and sustain a disciplined manufacturing culture focused on safety, quality, and continuous improvement.

Safety & Environmental Compliance

· Establish safe manufacturing practices for high-energy lithium-ion battery systems.

· Complete required training and safely work with systems operating at voltages up to 1,500 volts.

· Ensure appropriate controls are implemented for electrical hazards, energized work, short-circuit prevention, lifting operations, chemical handling, and battery assembly activities.

· Partner with Environmental Health & Safety (EHS) and Quality teams to develop Job Safety Analyses (JSAs), procedures, PPE requirements, and emergency response protocols.

· Promote safe behaviors through hands-on leadership and daily production activities.

The following responsibilities represent the primary duties of this role and are not intended to be an exhaustive list.

Qualifications

Required Qualifications

· Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, Industrial Engineering, or a related technical field, or an equivalent combination of education and industry background.

· 5+ years in a manufacturing engineering role with significant hands-on involvement in lithium-ion battery module and/or battery pack assembly operations.

· Proven success building, troubleshooting, or supporting battery packs in a production or manufacturing environment.

· Demonstrated ability to develop manufacturing processes from prototype builds through repeatable production implementation.

· Proficiency in creating manufacturing work instructions, process documentation, assembly procedures, and inspection requirements.

· History of training, mentoring, or leading manufacturing technicians and operators.

· Strong mechanical aptitude and proficiency with production tools, fixtures, torque equipment, electrical test equipment, and manufacturing systems.

· Skilled in root cause analysis, corrective actions, and continuous process improvement initiatives.

· Ability and willingness to spend significant time working directly on the manufacturing floor.

Preferred Qualifications

· 7+ years supporting battery module or battery pack manufacturing, EV, aerospace, defense, industrial battery, or other high-reliability manufacturing environments.

· Track record of launching, scaling, or transferring battery pack assembly operations between facilities or manufacturing partners.

· Familiarity with cylindrical-cell battery pack architectures.

· Working knowledge of battery interconnection technologies, including laser welding, resistance welding, ultrasonic welding, and mechanical busbar assembly.

· Background in pack-level electrical testing, insulation resistance testing, continuity testing, BMS integration, and end-of-line validation.

· Knowledge of PFMEA, APQP, Control Plans, process validation, and manufacturing readiness assessments.

· Familiarity with ISO 9001 or similar quality management systems.

· Background manufacturing battery systems for defense, aerospace, automotive, industrial, or other highly regulated industries.

· Understanding of battery transportation, safety, and performance standards, including UN 38.3 and relevant IEC, UL, SAE, or customer-specific requirements.

Work Environment

This position operates primarily within a manufacturing and engineering environment and requires substantial time spent on the production floor supporting battery pack assembly activities. The role routinely utilizes manufacturing equipment, testing devices, hand tools, computers, and other production-related equipment.

Physical Requirements

This position requires frequent standing, walking, bending, kneeling, reaching, lifting, and hands-on assembly work. The employee must be able to safely work around manufacturing equipment and battery systems and occasionally move materials and equipment weighing up to 50 pounds with or without reasonable accommodation.

Travel

No regular travel is required for this position.

Compensation & Benefits

Salary Range: $85,000.00 - $110,000.00 annually. The salary range for this exempt position will be determined based on the candidate's qualifications, experience, skills, and alignment with internal equity among current employees.

Benefits Offered:

• Medical, Dental, and Vision Insurance
• Life and Disability Insurance
• LTD and STD Insurance
• FSA and HSA
• 401(k) Retirement Match
• Paid Time Off (PTO) & Floating Holidays
• Paid Holidays
• Paid Parental Leave

Forge Nano Inc. is proud to be an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, veteran status, or any other protected status under applicable law.