Senior Process EngineerManufacturing Engineering • Weirton, WV • Full time • On-site

Are you ready to build America's energy future? Form Energy is an American manufacturing and energy technology company. We're revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what's possible, we're giving clean energy a whole new form!

In recent years, Form Energy has earned a number of accolades, including being named by TIME as a "Best Invention", MIT Technology Review as a "Top Climate Tech Company To Watch", and Fast Company as "One of the Next Big Things In Tech". We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States and production of our iron-air batteries is underway at our first high-volume manufacturing facility in West Virginia.

Working for Form Energy is more than just a job, it's a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing - might be the most exciting moment in the company's history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better.

Feeling energized to make a meaningful impact on the world? Then keep reading - you've come to the right place.

Role Description

Form Energy is hiring a Senior Process Engineer - Powder Mixing to join our world-class engineering team. Our team is responsible for designing, developing, and scaling cutting-edge electrode manufacturing processes for Form Energy's Iron-Air multi-day battery.

As a Senior Process Engineer, you will lead the development and optimization of powder mixing operations that are fundamental to the performance and reliability of our electrodes. Your expertise in powder handling, mixing, and scale-up will directly influence the quality, consistency, and throughput of our cathode manufacturing line. You will design and execute experiments, analyze process data, and collaborate with equipment and operations teams to ensure robust and safe scale-up of our mixing systems. This is a unique opportunity to take ownership of a critical process area while shaping the future of a transformative energy storage technology.

This role will be located at Form Factory 1 in Weirton, WV, which is just a short drive outside of Pittsburgh, PA. Relocation assistance is available.

What you'll do :

Develop, scale, and optimize powder mixing processes for high-volume electrode manufacturing.

Define process requirements and partner with equipment engineers to design, specify, and qualify mixing systems.

Characterize raw material properties (particle size, shape, surface area, flowability) and correlate them with mixing performance and electrode quality.

Lead experimental trials and data analysis to establish process windows, improve quality, and increase throughput.

Develop novel test methods to evaluate product quality and inform process window optimization strategies.

Be a champion for safety while scaling initial process designs to full production volume.

What you'll bring :

5+ years of experience with powder mixing, blending, or related powder handling processes in a manufacturing or pilot environment.

Demonstrated ability to scale powder processes from lab to production, with a track record of solving complex technical challenges.

Hands-on experience with industrial mixers (e.g., high-shear, plow, or ribbon mixers) and powder handling equipment.

Strong foundation in process characterization, statistical methods, and data-driven decision-making.

Excellent communication and organizational skills, with experience writing process, safety, and quality documentation.

Bachelor's degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a related field.

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Humanity is a cornerstone of Form Energy's culture, and we make sure our compensation and benefits reflect that. Form Energy offers competitive salaries, stock options, and a holistic benefits package to ensure all employees have what they need to thrive while working here.

When it comes to you and your family's health, we cover 100% of medical, dental, and vision premiums for full-time employees - and 80% of healthcare premiums for dependents. This starts from day one. We also offer at least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents), and generous vacation policies to give employees time to recharge when needed.

To build America's energy future, we need everyone at the table. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.

If you may require reasonable accommodations to participate in our interview process, please contact accommodations@formenergy.com. Requests for accommodations will be treated with discretion.

Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.