Staff 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

We are looking for Process Engineers to join our Advanced Manufacturing Engineering team. Together, we're responsible for designing, developing, optimizing and scaling up a new class of battery manufacturing assembly processes for Form Energy's Iron-Air multi-day battery.

This role calls for a versatile Process Engineer who expertly blends a data-centric approach with a practical understanding of manufacturing operations. You will leverage Experimental Design (DoE) and advanced statistical data analysis (JMP, Minitab, SPC fundamentals) to understand process tradeoffs, solve complex problems through structured root cause analysis, and confidently champion data-backed improvements. Your expertise extends to hands-on ownership of medium to high-volume equipment, applying a strong foundation in materials and mechanical forces to seamlessly scale processes from initial development trials to full production, ensuring robust product quality achieved through capable and controlled processes.

Your work will make a significant and daily impact on cutting-edge battery technology that will revolutionize the electric grid and bring major change to grid reliability and sustainability. This is a fantastic opportunity to join a company with a direct impact on the nature of energy storage and renewables.

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 :

Lead the development and optimization of novel battery manufacturing equipment with a data driven approach

Develop and maintain FMEA, Process specifications, measurement systems GR&R, Control plan, statistical process control (SPC), and quality inspection methods (incoming, outgoing, and in-process.)

Provide data-driven feedback to the Design team (DFM) to simplify manufacturing processes

Develop novel test methods to evaluate products in real time during production.

Partner closely with our Manufacturing Equipment to design, build, install, and run processes on first-of-kind manufacturing equipment.

Collaborate with the product design team, R&D, quality, and supply chain, to translate product requirements into a manufacturing process that achieve our company targets.

Prioritize safety across all aspects of manufacturing, ranging from process design to scaled manufacturing

Demonstrate ownership and accountability, making a major impact on our battery technology by commissioning and owning novel processes in a fast-paced manufacturing environment.

Mentor, guide, and support team members with your expertise and practical experience

What You'll Bring :

5+ years of experience in a fast-paced manufacturing or production environment, ideally in process engineering, NPI or scale-up

Expertise in process engineering principles, statistical analysis, and quality management systems for process optimization and improvement (FMEA, SPC, RCA, DoE)

Expertise in using statistical methods to make process development decisions (using JMP or Minitab, python or equivalent)

Experience owning manufacturing processes and showing accountability for their quality, throughput, yield, and overall success (Examples : joining processes for metal & plastics, leak testing, electrical testing, in-line quality checks)

Experience authoring process, safety, and quality documentation for best-in-class practices

Extensive hands-on experience with medium to large equipment and a desire to roll up your sleeves and fill the gaps where necessary

Bachelor's degree in Chemical Engineering, Materials Science, Mechanical Engineering, Manufacturing Engineering, or Equivalent

Excellent communication and organizational skills

#LI-Onsite

#LI-DL1

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.