Staff Process Engineer, Leak Testing Manufacturing Engineering * Weirton, WV * Full time

Are you ready to build America's energy future? Form Energy is an American energy technology and manufacturing company. We are pioneering a new class of iron-air batteries to enable our electric grid to run on clean, reliable and affordable energy, every day of the year.

Over the past few years, Form Energy and our iron-air batteries have received numerous accolades, including being named a "Best Invention" by TIME, a "Top Climate Tech Company To Watch" by MIT Technology Review, and "One of the Next Big Things in Tech" by Fast Company. We are making rapid progress on our mission of delivering energy storage for a better world, and are growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States. Pilot production of our iron-air batteries has already begun, and this year, production will take off to high volumes at our new factory in West Virginia.

Working for Form Energy is more than just a job, it's a chance to be part of something extraordinary. And right now might be the most exciting moment in the company's history to join. We are assembling a team of exceptionally 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 Engineer, specializing in testing, to join our Advanced Manufacturing Engineering team. Together, we're responsible for designing, developing, optimizing, and scaling up new manufacturing processes for Form Energy's Iron-Air multi-day battery.

In this role, you will play a crucial role in developing new methods and processes to ensure the stability of novel manufacturing of our core battery assembly technologies. You will focus on developing in process testing, primarily leak testing, but also Hipot and weld quality (ie resistance). 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 testing processes, focusing on leak testing but also encompassing Hipot / continuity testing, for novel battery manufacturing technologies.

Partner closely with our Equipment team to design, build, install, and run 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.

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, making a major impact on our battery technology owning novel testing methods and processes from concept to high volume production in a fast-paced environment.

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

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

Mentor, guide, and support Jr 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 testing processes, such as leak test, Hipot, and continuity testing for welded joints, and a desire to roll up your sleeves and fill the gaps where necessary.

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

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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 a clean and equitable energy future, we need everyone at the table. We strive to form a team as diverse as the communities we will serve with our technology, and are committed to maintaining an inclusive environment for all employees. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.