Staff Manufacturing Engineer, Welding

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 seeking a Staff Manufacturing Engineer specializing in welding and bonding processes to act as a Joining Specialist.  In this position, you will be part of our  Advanced Manufacturing Engineering team responsible for developing, optimizing, and scaling new manufacturing processes for Form Energy’s Iron-Air multi-day battery.

As a Joining Specialist, you will play a crucial role in defining the processes used to seal our cell vessels, create electrical interconnects, and assemble auxiliary systems. You will focus on developing highly capable processes that enable the product design to meet our cost and performance targets while ensuring the stability of novel manufacturing processes. Your work will make a significant and daily impact on our mission to revolutionize grid reliability and sustainability.

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 joining processes, such as welding (metal and plastic), and adhesives bonding for novel battery manufacturing technologies.

• Partner closely with our equipment team to design, install, and commission equipment for our first-of-kind manufacturing processes.

• Collaborate with the product design team, R&D, quality, and supply chain, to translate product requirements into process and testing requirements. 

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

• Provide data-driven feedback to the Design team to simplify product design for improved manufacturability (DFM)

• Ensure highly capable processes are developed and demonstrated ahead of detailed equipment design. Measure process capability and evaluate limit samples through bench top testing.  

• Conduct process capability studies, utilize statistical analysis tools (e.g., Design of Experiments). Lead troubleshooting efforts to identify root causes of manufacturing issues and implement corrective actions to prevent recurrence while optimizing processes.

• Develop and maintain PFMEA, process specifications, measurement systems GR&R, control plans, and quality inspection methods (incoming, outgoing, and in-process).

• Demonstrate ownership and accountability for novel joining processes from concept to high volume production in a fast-paced environment.

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

• Drive yield, quality, and performance through a data-driven approach.

What You’ll Bring: 

• Bachelor’s degree in Chemical Engineering, Materials Science, Mechanical Engineering, Manufacturing Engineering, or equivalent.

• 7+ years of experience in a fast-paced manufacturing or production environment, ideally in process engineering or manufacturing engineering.

• Hands-on experience with joining processes, such as welding.

• Proficiency in process engineering principles, statistical analysis, and quality management systems for process optimization and improvement.

• Comfort using statistical methods to make process development decisions (using JMP, Minitab, or equivalent).

• Experience owning manufacturing processes and showing accountability for their quality, throughput, yield, and overall success.

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

• Excellent communication and organizational skills.

• Direct experience with batteries is a plus.

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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 [email protected]. 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.