As the global shift toward electric vehicles and sustainable energy accelerates, material scientists play a pivotal role in shaping our future. Engineers must find ways to make vehicles lighter, batteries more efficient, and manufacturing processes more environmentally friendly. Dr. Cassondra Brayfield stands at the intersection of these changes.
As a senior research and development engineer working in the powder metallurgy industry, Dr. Brayfield is helping transform iron powder into a vital component of battery innovation, all while mentoring others, leading community initiatives, and redefining what it means to succeed in STEM.
A Career Forged by Curiosity and Grit
“I never felt like I was more gifted than any of my classmates,” Dr. Brayfield says. “I was the kid who was up all night drinking energy drinks, waking up early to restudy, cramming before the test and retaking courses. I still made it this far.”
After earning a Bachelor of Applied Science at Rensselaer Polytechnic Institute, she interned at Corning Incorporated before joining Intel Corporation in Arizona. “I found my first role monotonous and slow, which was made worse by being on-call at a 24-hour fab, so I wrote a step-by-step manual that reduced my on-call time by 80%,” she recalls. Dr. Brayfield advanced into a yield engineering role while working toward her master’s at Arizona State University. In 2023, she earned a Doctor of Philosophy from the University of California, Davis.
From Iron to Innovation
In her current role, Dr. Brayfield focuses on repurposing iron powder for battery materials. “Cars need to be lighter so they can carry batteries instead of gas,” she says. “There are fewer tons of iron on the road. My role is to find ways we can take the powder we already produce and use it in batteries.”
Dr. Brayfield brings clean room expertise from Intel into her current lab work. “I’m always considering how the lab-scale results will translate to customer needs and how our process can help. If we can provide more battery material feedstock and get more cars off of fossil fuels, we could be saving the world.”
Teaching, Mentoring, and “Sending the Elevator Back Down”
Completing her dissertation with no prior background in synthetic chemistry helped Dr. Brayfield secure her current role: “It helped me land my dream job.” However, she values mentorship just as much as her work. “I regularly mentor two to three young professionals at a time,” she says. “It’s my mission to ‘send the elevator back down.’”
Dr. Brayfield works with students through Skype a Scientist and Project Lead the Way, and supports former foster youth in their pursuit of college degrees. “I care about my students, colleagues, and co-workers,” she adds. “I want them to know that with enough persistence, anything is possible.”
Recognized for Excellence and Advocacy
Dr. Brayfield received the Outstanding Graduate Student Teaching Award from UC Davis and has been featured in industry publications. She proudly honors her Puerto Rican and German heritage and serves as a visible advocate for women, LGBTQ, and Hispanic representation in STEM. “Representation matters,” she insists.
Dr. Brayfield also helps teachers introduce material science in elementary classrooms. “If kids can see what science looks like early on, they’re more likely to believe they can do it,” she says.
Looking Forward: Battery Tech and Big Dreams
Over the next five years, Dr. Brayfield hopes to either continue working to provide the materials we need to fuel our battery future, either with her current company or with a major battery company, such as Duracell or Panasonic. “My goal is to drive innovation and sustainability in battery technology. I want to climb the ladder and make an impactful change.”
Dr. Brayfield is also a committed volunteer who organizes annual fundraisers for Feed My Starving Children and is currently launching a river cleanup initiative near the Delaware River. “I’m serious about science, passionate about people and always looking for ways to help,” she says.
“I want to save the world or get rich trying,” Dr. Brayfield says with a laugh. “Either way, we’ll do it with purpose.”
Note: The views expressed in this article belong to Cassonda Brayfield as an individual and do not represent those of her employer, customers, or suppliers.
