Application Engineer

Ensurge is seeking an Application Engineer to serve as the technical customer liaison to translate customer requirements and constraints into product specifications, collaborate with product engineering to define and lead system integration, and facilitate the product's final validation. This role owns the translation of customer use cases into clear technical requirements and closing the loop through data-driven feedback into design-of-experiments (DoE), product improvements, and roadmap decisions.

The ideal candidate has deep experience working alongside both technical and commercial teams to integrate advanced battery solutions based on customer specifications. This individual also understands how to adapt to application-specific constraints, such as form factor, volumetric energy density, reliability, safety, and lifecycle performance-ideally across high-reliability applications, including medical devices, IoT solutions, and/or consumer electronics.

Key Responsibilities

Customer Application & Requirements Ownership

• Serve as the technical owner of customer requirements, translating use cases into measurable electrical, mechanical, packaging, environmental, and reliability specifications

• Support customer engagements from technical due diligence to RFx, design reviews, validation, sampling, and pre-production readiness

• Partner with customers to define acceptance criteria, test plans, and performance trade-offs aligned with microbattery constraints

• Develop and maintain application-specific documentation, including requirements matrices, compliance reports, and datasheets

Cell Validation & Test Support

• Support cell-level validation plans performed by product engineering, covering electrical performance, cycling, safety, environmental robustness, and mechanical integrity

• Ensure test coverage reflects real-world application conditions (duty cycles, temperature profiles, load cases, packaging constraints)

• Coordinate with internal and external test partners to ensure repeatable, traceable, and standards-aligned testing

Failure Analysis (FA) & Root Cause Investigation

• Lead failure analysis efforts for cell, process, or performance deviations using electrochemical, mechanical, and materials-based methods

• Correlate failure modes to design choices, materials, process windows, or usage conditions

• Drive corrective and preventive actions (CAPA) in collaboration with R&D, process engineering, and manufacturing teams

DoE Planning & Feedback Loops

• Support product engineering DoEs to optimize cell performance, reliability, and manufacturability

• Close the loop between test results, FA insights, and design/process updates

Cross-Functional Collaboration

• Provide input to roadmap decisions by quantifying performance trade-offs, risks, and scalability implications

• Collaborate with cell design, validation, process engineering, manufacturing, quality, product, and commercial/business development teams

• Support internal phase-gate reviews with application-driven validation evidence

• Help align customer commitments with technical feasibility, timelines, and production readiness

• BS or MS in Chemical or Mechanical Engineering, Materials Science, Electrochemistry, or related field

• 3-6+ years of experience in battery cell engineering, application engineering, or validation

• Hands-on experience with battery cell qualification, test planning, and requirements verification

• Strong background in failure analysis, root cause investigation, and data interpretation

• Experience executing DoEs and using experimental results to guide design or process decisions

• Ability to communicate complex technical findings clearly to customers and cross-functional teams

Preferred Qualifications

• Experience with solid-state, lithium-metal, or advanced lithium-based battery systems

• Exposure to microbatteries in applications related to medical devices or other high-reliability applications

• Familiarity with requirements and lifecycle tools (e.g., JAMA, Polarion, Arena, Jira, Confluence)

• Prior customer-facing experience supporting custom battery solutions