Staff Process Development Engineer

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 Staff Process Development Engineer to lead the invention and scale-up of new manufacturing processes for our Gas Diffusion Electrode (GDE). As part of our GDE Advanced Manufacturing team, you will lead new process development for GDE fabrication — from early feasibility through pilot-line qualification — in collaboration with Materials Science, Product Development, Manufacturing Engineering, and Quality teams. This is an exciting opportunity to help shape and be part of the growth of a fast-moving company with breakthrough technology and an incredible mission!

Relocation Assistance is available.

What you'll do:

• Lead development of new and next-generation GDE manufacturing processes, from bench-scale concept through pilot-line qualification

• Design and execute experiments to characterize and optimize process parameters against quality, throughput, and performance targets

• Partner with Materials Science and Product Development to translate new material formulations into manufacturable, scalable processes

• Drive root-cause investigations for process and quality excursions, translating experimental data into corrective actions

• Define process specifications and control plans, and own technical handoff of new processes to Manufacturing Engineering for scale-up

• Train and mentor engineers and technicians supporting process development trials

• Be a champion for safety in the development of new processes and equipment

What you'll bring:

• 7+ years of experience in process development or manufacturing engineering, ideally in batteries, electrodes, or advanced materials manufacturing

• Demonstrated experience designing and executing experiments and translating results into robust, production-ready processes

• Hands-on experience with material processing equipment and process characterization techniques

• Experience using statistical methods to guide process development decisions

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

• Excellent communication and organizational skills, with a proven ability to lead cross-functional technical initiatives independently

Where you'll work:

This role is based at Form Factory 1 in Weirton, WV—an easy commute from the city of Pittsburgh, PA. This 550,000-square-foot facility is our hub for high-volume battery production and a leader in the new era of American energy manufacturing. Relocation assistance is available.

#LI-Onsite

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.