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About the Role
T1 Energy is seeking a Cell Metallization Process Engineer for its G2 solar cell fab in Rockdale, Texas. This role focuses on the back-end manufacturing process for solar cells, specifically screen printing, firing, and laser systems, which are critical for cell efficiency at scale. You will be responsible for developing, optimizing, and sustaining the metallization process for TOPCon solar cells, ensuring ohmic contact and minimizing defects. Your work will contribute to the technical foundation and future roadmaps for T1_G2's metallization processes.
Responsibilities
- Own statistical process control for metallization, including process excursions in efficiency, microcrack yield, and paste weight, and isolate parameters affecting Voc, Isc, fill factor, and electroluminescence/photoluminescence.
- Maintain controlled documentation on screen printing process parameters and initiate DOEs to optimize process tuning.
- Oversee the ramp-up of the screen printing module and the testing and sorting module.
- Develop front and rear contact metallization processes for TOPCon solar cells, optimizing furnace thermal profiles, ohmic contact formations, and paste rheology while minimizing contact resistance and defects.
- Identify interfacial process parameters specific to the metallization module, anti-reflective deposition modules, and emitter formation diffusion modules.
- Drive process characterization and DOE execution across paste formulation, mesh and emulsion parameters, squeegee dynamics, and firing profiles.
- Qualify new paste materials and screen suppliers, evaluating next-generation metallization solutions.
- Troubleshoot metallization-related yield losses and process excursions with equipment engineering teams.
- Develop metallization-related process initiatives for future-state production and optimize interactions with T1_G1.
- Support technology transfer and scale-up activities as G2 ramps to full production capacity.
Requirements
- Strong understanding of electrical characteristics and qualifying metrics for solar-semiconductor materials.
- Expertise in tools for parameter characterization (TLM, pulling force tester, vision systems, four-point probe) is preferred.
- Deep knowledge in solar cell metallization: screen printing, contact firing, and paste chemistry.
- Hands-on and technically precise with the ability to connect print process variables to electrical cell performance outcomes.
- Data-driven approach to process development and troubleshooting.
- Strong cross-functional collaboration skills.
- Detail-oriented and disciplined in documentation.
- Ability to thrive in a fast-moving, high-volume fab environment.
- Obsession with the theory of transistor action and William Shockley is a strong plus.
Skills
- Solar cell metallization
- Screen printing
- Contact firing
- Paste chemistry
- Process development
- Process optimization
- Statistical Process Control (SPC)
- Design of Experiments (DOE)
- Data analysis
- Python
- JMP
- Excel
- SOP writing
- Process specification
- Engineering reports
Location
- Rockdale, Texas
Work Type
- Full-time
Experience Level
- 3+ years of process engineering experience in solar cell manufacturing
Education Level
- Bachelor's degree or higher in Materials Science, Chemical Engineering, Mechanical Engineering, Electrical Engineering, Physics, or a related field.
About the Company
- T1 Energy is bringing solar manufacturing back to the U.S. by building a domestic solar supply chain.
- Our mission is to invigorate America with scalable, reliable, and low-cost energy.
- Our fully operational 5GW solar module facility in Wilmer, Texas, can manufacture more than 20,000 modules every 24 hours.
- We're focused on building advanced American manufacturing and we're passionate about engineering a better future filled with abundant energy.
- We move fast, expect accountability, and treat people with respect.
- We have a no-jerks policy: we don't tolerate big egos, bad behavior or 'that's not my job attitude'. Be sharp, be honest, be human. If you can hold the line and have a sense of humor, you'll fit right in.
Equal Opportunity
- T1 Energy is an Equal Opportunity Employer.
- We are committed to creating an inclusive environment for all employees and applicants and do not discriminate on the basis of any legally protected characteristics.