Senior Mechanical Engineer, Manufacturing R&D

About the role

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 Mechanical Engineer to join our Core Technology Hardware team. In this role, you will lead the design, development, and deployment of custom manufacturing equipment and precision assembly fixtures to support our low-volume battery test vehicle manufacturing lines.

As a technical leader within our manufacturing R&D group, you will bridge early-stage technology discovery and physical execution. This is an extraordinarily collaborative role: you will sit at the center of our hardware feedback loop, working side-by-side with test vehicle design engineers, hands-on assembly technicians, battery scientists designing experiments, and the test infrastructure and execution teams who bring our testing operations to life. 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

• Develop novel designs of mechanical and electromechanical manufacturing equipment, ranging from manual assembly fixtures to semi-automated and fully automated tooling
• Drive new manufacturing line bring-ups as existing products evolve or new test vehicles come online, continuously triaging existing line capabilities against new product revisions and custom R&D experiments
• Identify and mitigate manufacturing risks early through design reviews, DFMEA/PFMEAs, process control plans, and hands-on evaluations of vendor proposals
• Lead technical assessments of R&D build processes on the shop floor, identifying bottlenecks and driving continuous improvements in cycle time, yield, and quality.
• Fabricate custom or one-off test vehicles upon request-delivering everything from quick, scrappy proof-of-concept assemblies to highly polished, specialized testing units.
• Establish standards for equipment design, vendor management, commissioning, and cross-team data collaboration. Bring exceptional attention to detail to technical presentations, engineering drawings, and cross-functional project leadership.
• Lead by example and mentor junior engineers, building a culture of technical rigor in equipment design, documentation, and repeatable manufacturing execution
• Mentor manufacturing R&D team members, leveraging a proven track record of building and documenting repeatable manufacturing processes and equipment to elevate team capabilities.

What You'll Bring

• Bachelor’s degree in Mechanical Engineering, Electromechanical Engineering, or related field with 4+ years of relevant experience (battery or energy systems experience is a plus).
• Hands on design and build experience.
• Proficiency in mechanical CAD tools, software tools for project planning, and PDM/ERP systems.
• Demonstrated experience in medium to high volume manufacturing lines of electromechanical products including new process development, value engineering exercises, and time-study cost savings efforts.
• Excellent problem-solving skills, with the ability and enthusiasm to balance safety, rigor, and speed.
• Strong communication and collaboration skills with a solution-oriented mindset when faced with spur of the moment obstacles.

• #LI-Onsite
• #LI-LN1

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.

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.