Next-Gen Energy in Motion: Leading the Scale-Up of Li-ion

Client Overview

Founded in 2006 and headquartered in Carlsbad, California, our client is a fast-growing innovator at the forefront of the clean energy revolution. The company designs and manufactures silicon-based lithium-ion (Li-ion) batteries that deliver the highest energy density in the world, exceptional safety, and performance in extreme temperatures. With over 40 US and international patents and more than 100,000 units shipped, the company serves critical sectors including Defense, Aerospace, Medtech, and Electric Vehicles.

Their technology is integral to driving forward electric mobility, enhancing renewable energy systems, and enabling grid storage solutions. Sustainability is core to their mission, reflected in their responsible sourcing, high industry standards, and commitment to environmentally responsible manufacturing practices. Their success is powered by a team of professionals passionate about innovation, performance, and environmental stewardship, making them a leading force in advanced energy storage solutions.

The Challenge / Mandate

The company needed a seasoned Vice President of Manufacturing to lead the transition from R&D and pilot production to full-scale, high-volume manufacturing of their Li-ion battery technology. The role required overseeing manufacturing, engineering, and quality teams while building a greenfield megawatt-hour cell manufacturing facility.

Key objectives included:

• Spearheading manufacturing operations from the existing pilot line through to the new high-volume production site
• Building and managing teams to deliver best-in-class manufacturing and quality performance
• Driving process improvements to ensure efficient scale-up and yield optimization
• Establishing and monitoring KPIs for quality control, compliance, and operational excellence
• Supporting a high-performance culture aligned with company growth and productivity goals

This was a highly specialized and mission-critical mandate requiring deep Li-ion battery cell manufacturing knowledge and successful greenfield plant development experience.

Search Strategy

The search focused on candidates with deep technical and operational expertise in lithium-ion battery manufacturing. The following criteria were prioritized:

Experience & Background:

• 8+ years in manufacturing, with significant experience in Li-ion cylindrical cell production
• Successful track record establishing greenfield manufacturing operations
• BS in Mechanical, Industrial, or Manufacturing Engineering (MBA preferred)

Functional & Leadership Competencies:

• Demonstrated ability to translate technical expertise into tactical execution
• Skilled at scaling production from pilot to high-volume environments
• Strong team leadership and talent development capabilities

Soft Skills & Cultural Fit:

• High-energy, open-minded, and solution-oriented mindset
• Excellent prioritization, communication, and cross-functional collaboration
• Ability to thrive under pressure while building a positive work culture
• Candidates with direct experience in scaling battery cell operations and an ability to be onsite full-time in Carlsbad were prioritized.

The Placement

ECA presented a strong slate of candidates, and the finalist selected brought over 20 years of R&D and manufacturing experience across lithium-ion batteries, solar PV, and semiconductor industries. He possessed deep expertise in cylindrical cell manufacturing and demonstrated a successful track record leading operations, technology development, and customer service.

His technical specialization includes lithium-ion silicon anode development, dielectric and metal film deposition, and electrolyte materials. He also fulfilled the client’s requirement of being fully onsite to lead the scale-up and greenfield efforts hands-on.

The Outcome

The new VP of Manufacturing is now responsible for scaling up the company’s pilot line into high-volume manufacturing across cylindrical, prismatic, and pouch battery formats. He oversees all aspects of the company’s manufacturing operations, including process development, quality control, team building, and supply chain management. His leadership marks a major step forward in the company’s transition from innovation to large-scale production, helping meet growing global demand for advanced energy storage solutions.