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Form Energy is seeking a Senior Mechanical Design Engineer to join the Structures Engineering team, responsible for designing the structure, enclosure, and sealing systems for utility-scale multi-day iron-air battery storage systems. This role focuses on bringing components and assemblies from concept through mass production, with emphasis on FEA-driven structural design, weatherproofing, and manufacturability of metal enclosures.
Key responsibilities include creating white-paper designs for next-generation battery packs optimized for high-volume production; performing structural analysis using ANSYS FEA and hand calculations; collaborating with test engineers to establish material libraries and validate designs through test-FEA correlation; presenting designs and analysis results in design reviews; conducting failure root cause analysis; and traveling up to 20% to other Form Energy offices or vendor sites.
You will work cross-functionally with designers and test engineers to interrogate the design space and select appropriate validation methods. The role emphasizes balancing structural optimization with design for manufacturability, weight reduction, and cost-down, particularly for sheet metal, weldments, and sealing systems.
Required qualifications: Bachelor's degree in Mechanical Engineering or related field with 4+ years of industry experience in mechanical design and structural analysis. Must have experience designing complex mechanical structures using FEA, proficiency in SolidWorks CAD modeling and GD&T (ASME Y14.5) drafting, and component design for mass manufacturing and assembly (DFMA), especially sheet metal, stampings, and weldments. Strong sense of urgency and self-driven approach to meeting difficult schedule targets required.
Form Energy is a venture-backed manufacturing and energy technology company founded in 2017, headquartered in Somerville, MA. The company has been recognized 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." Production of iron-air batteries is underway at their first high-volume manufacturing facility in West Virginia, with contracts signed with leading US electric utilities. Relocation assistance is available.
