​​Dr. Samuel Madden is a battery expert and engineering consultant specializing in advanced energy storage systems, battery safety, and product validation for electrified mobility and consumer product applications. He brings over a decade of cross-functional experience in battery manufacturing, failure analysis, system integration, and technical leadership across both industry and litigation contexts.

​Before joining Secretariat, Dr. Madden served as Director of Battery Analytics and Validation at Factorial Energy. There, he led the validation of the world’s first 100+ Ah semi-solid-state battery deployed in a western demonstration vehicle and managed joint development efforts with Mercedes-Benz and Stellantis. He directed the development of advanced digital tools for battery testing and safety, including protocol verification systems, alert features, and digital twin modeling. Dr. Madden also oversaw the design and launch of a high-capacity lab featuring more than 2,000 channels, abuse testing, and ARC capabilities.

​Prior to that, Dr. Madden spent nearly nine years as a Managing Engineer at a leading global engineering consulting firm. His work focused on lithium-ion battery failure analysis, intellectual property disputes, safety investigations, and technical reporting for government and legal clients. He served as a testifying expert witness, advised the U.S. Consumer Product Safety Commission, and played a central role in high-profile investigations, including the Samsung Note 7 recall. His experience spans cell and pack design audits, supplier quality analysis, BESS system fires, and patent validity assessments.

​Beyond his deep expertise in battery systems, he also conducted hundreds of failure analysis investigations of consumer products, electronics, medical devices, and industrial equipment. These investigations often involved root cause analysis related to corrosion, fracture, fatigue, thermal events, and electrical overstress, spanning a myriad of industries from automotive, to consumer electronics, to medical technology, to aerospace.

​Dr. Madden holds a Ph.D. in Materials Science and Engineering from the University of Virginia, where his research focused on electrochemistry and corrosion science, and a B.S. in Physics from Union College. He is a licensed Professional Engineer in Metallurgy (Texas) and an active member of multiple technical societies, including the Electrochemical Society, IEEE, and SAE. He has contributed to national battery safety initiatives, including the DOE Energy Storage Safety Strategic Plan and IEEE P2686 guidelines. His publications cover topics ranging from lithium-ion cell degradation to advanced diagnostic methods for materials and battery systems.