Process Engineer, Metallization
T1 Energy · Rockdale
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. By the time you finish reading this paragraph, we will have produced two solar panels that will power American homes and fuel domestic AI. We're focused on building advanced American manufacturing and we're passionate about engineering a better future filled with abundant energy.
The Role
T1 Energy is looking to hire a Cell Metallization Process Engineer to join our process engineering team at our G2 solar cell fab in Rockdale, Texas. This is a hands-on technical role for an engineer who owns the back-end manufacturing process for solar cells: screen printing, firing, and laser systems that make or break cell efficiency at scale.
At G2, we're manufacturing TOPCon solar cells at high volume, and metallization is one of the most critical and nuanced steps in the process. You'll be responsible for developing, optimizing, and sustaining the metallization process critical to creating ohmic contact to the front emitter and to the rear poly-Si / tunnel-oxide stack. You will develop and iterate DOEs for metal paste selection, “golden cell” calibrations and multi-lane matching, firing profiles, and laser current density. Additionally, you will own the process qualification and integration of the metallization module with upstream thermal treatment equipment (PECVD) and downstream QA/QC and packaging. Your work will contribute to the technical basis for T1_G2’s metallization campaigns and technology roadmaps. If you've spent your career in solar cell metallization and you're ready to do it at a scale that matters for American energy, this is your role.
What You'll Do
Own statistical process control for metallization at G2, including process excursions in efficiency, microcrack yield, and paste weight, and isolate the parameters that move Voc, Isc, fill factor, and electroluminescence/photoluminescence.
Maintain controlled documentation on screen printing process parameters and initiate DOEs across both Process and Equipment Engineering teams to isolate and optimize process tuning.
Oversee the ramp-up of the screen printing module (product manufacturing via printing, firing, light injection, and laser systems) and the testing and sorting module (efficiency grading by current-voltage profiles and fill factors with additional EL/PL analysis).
Develop front and rear contact metallization processes for TOPCon solar cells with a focus on optimizing furnace thermal profiles, ohmic contact formations, and paste rheology/properties while minimizing contact resistance, environmental contamination, and process-related print defects (including those stemming from upstream process interfaces).
You will work with an interdisciplinary process team, including thermal diffusion and deposition group leaders, to 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 while managing the risk of silver diffusion and metal-silicon interfaces across distinct layers.
Qualify new paste materials and screen suppliers, working closely with vendors to evaluate and introduce next-generation metallization solutions.
Partner with equipment engineering teams to troubleshoot metallization-related yield losses and process excursions, including print quality defects, adhesion failures, contact resistance variation, and firing window issues.
Partner with T1’s Technology teams to develop metallization-related process initiatives for future-state production, and, additionally, to optimize metallization-related process interactions with T1_G1, our 5GW Dallas solar module plant.
Support technology transfer and scale-up activities as G2 ramps to full production capacity.
Who You Are
Strong understanding of the electrical characteristics and qualifying metrics for solar-semiconductor materials including open circuit voltage, short circuit current, series resistance, fill factor, J0e, bandgap, and, not limited to, minority carrier lifetimes. Additional expertise in the tools required for parameter characterization is preferred (TLM, pulling force tester, vision systems, four-point probe)
Deeply knowledgeable in solar cell metallization — screen printing, contact firing, and paste chemistry are your home turf.
Hands-on and technically precise, with the ability to connect print process variables to electrical cell performance outcomes.
Data-driven in your approach to process development and troubleshooting — you design experiments that answer the right questions and let the data lead.
A strong cross-functional collaborator who works effectively with equipment, integration, quality, and yield teams.
Detail-oriented and disciplined in documentation — you know that a process that isn't documented isn't controlled.
Energized by the challenge of optimizing a high-impact process in a fast-moving, high-volume fab environment.
Strong plus to be obsessed with the theory of transistor action and William Shockley.
Qualifications
Bachelor's degree or higher in Materials Science, Chemical Engineering, Mechanical Engineering, Electrical Engineering, Physics, or a related field.
3+ years of process engineering experience in solar cell manufacturing with direct, hands-on experience in metallization processes.
Demonstrated expertise in screen printing process development and optimization for solar cell applications.
Strong working knowledge of silver and/or aluminum paste chemistry, contact formation mechanisms, and firing furnace control.
Experience with TOPCon or other advanced cell architectures (PERC, HJT, IBC) is strongly preferred.
Familiarity with in-line metrology tools for print quality inspection, contact resistance measurement, and IV characterization.
Experience with DOE methodology, SPC, and statistical data analysis for process optimization.
Proficiency with data analysis tools such as Python, JMP, or Excel.
Strong documentation skills and experience writing SOPs, process specs, and engineering reports.
The T1 Way
We move fast, expect accountability, and treat people with respect. We also 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.
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.
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