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Form Energy is seeking an experienced Senior Controls Engineer to join their manufacturing team in Weirton, WV. The company manufactures long-duration iron-air battery systems for grid-scale energy storage, with production underway at their first high-volume facility.
In this role, you will design, develop, and commission novel manufacturing equipment and control systems for battery component production. You'll report to the Senior Manager of Central Equipment Engineering and lead a growing equipment engineering team. Your focus will span electromechanical control systems for high-volume automated process equipment, robotic cells, servo-actuated mechatronic systems, and utilities infrastructure, progressing from subsystem development to full system integration in a manufacturing environment.
Key responsibilities include: architecting control system hardware and I/O mapping; developing Sequences of Operations; performing electrical system analysis (short-circuit, thermal, power consumption); selecting sensors, actuators, and instrumentation; participating in equipment conceptual design; laying out NFPA79/NEC/UL508A-compliant electrical control panels; writing and debugging controls logic in ladder logic and structured text; and characterizing equipment for production deployment.
You'll work at the intersection of control system design, process engineering, and manufacturing operations, collaborating with technical and operational teams across the organization.
Required qualifications: Bachelor's degree in Electrical or Mechanical Engineering; 7+ years hands-on controls or robotics engineering experience with automation and electromechanical systems; proficiency with UL 508A and NFPA 70E standards; advanced programming skills in ladder logic and structured text; experience with Siemens and Rockwell platforms; Safety PLC experience; familiarity with industrial communications protocols (PROFINET, EtherNet/IP, MODBUS TCP, serial); experience programming 6-axis industrial robots (Fanuc, Yaskawa, Kuka, ABB); vision inspection system integration (Keyence, Cognex, Zebra); hardware selection and integration for industrial automation; electrical schematic design in CAD (AutoCAD Electrical preferred); and proven ability to design fault-tolerant systems with error handling.
Relocation assistance is available. The facility is a 550,000-square-foot hub for battery production, conveniently located near Pittsburgh, PA.
