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Form Energy is seeking a Senior Controls Engineer to join the Manufacturing Control and Execution Systems - Automation team at Form Factory 1 in Weirton, WV. This role is central to designing, developing, and deploying control systems for Form Energy's iron-air battery manufacturing operations.
You will report to the Controls Engineering Manager, Automation, and lead the design, programming, and deployment of complex industrial control systems (PLC/HMI/SCADA) for novel battery manufacturing equipment. Key responsibilities include serving as technical lead for automation projects, coordinating cross-functionally with Robotics, Vision, and SCADA teams to ensure systems meet technical requirements on schedule. You will develop and test PLC-to-MES data transactions and tracking handshakes to ensure seamless manufacturing execution and data integrity.
You'll partner with external equipment vendors to enforce Form Energy standards, conducting Factory and Site Acceptance Testing (FAT/SAT). The role requires providing expert-level electrical and controls support to resolve escalated production issues, minimizing downtime and improving process throughput. You will mentor and provide technical guidance to junior engineers, fostering a culture of excellence and high performance.
The ideal candidate brings 6+ years of applied experience designing and troubleshooting industrial control systems in high-volume manufacturing. Advanced proficiency in Siemens TIA-Portal and Rockwell Studio 5000 is required, along with practical experience with SCADA and HMI platforms (Ignition Perspective, Siemens WinCC, or Rockwell FTView). Strong technical foundation in functional safety programming (ProfiSafe and CIP Safety protocols) is essential. You should have expertise in reading and interpreting complex electrical schematics, experience with data analysis tools (iba or Octoplant), and familiarity with integrating vision systems and barcode scanners (Keyence or Cognex) into automated workflows.
A Bachelor's degree in Electrical Engineering, Mechatronics, or related field (or equivalent practical experience) is required. Excellent technical communication skills, pragmatic problem-solving abilities, and a collaborative approach are critical. You'll thrive on complexity, maintain intellectual curiosity about industrial automation trends, and be comfortable with a rotating on-call schedule for mission-critical manufacturing support. Relocation assistance is available.
