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Form Energy is hiring a Staff Process Development Engineer to lead the invention and scale-up of new manufacturing processes for Gas Diffusion Electrodes (GDE) at their high-volume battery production facility in Weirton, WV. This is a technical leadership role within the GDE Advanced Manufacturing team, where you will drive process development from early feasibility through pilot-line qualification.
Key responsibilities include:
- Leading development of new and next-generation GDE manufacturing processes, from bench-scale concept through pilot-line qualification
- Designing and executing experiments to characterize and optimize process parameters against quality, throughput, and performance targets
- Partnering with Materials Science and Product Development teams to translate new material formulations into manufacturable, scalable processes
- Driving root-cause investigations for process and quality excursions, translating experimental data into corrective actions
- Defining process specifications and control plans, and owning technical handoff of new processes to Manufacturing Engineering for scale-up
- Training and mentoring engineers and technicians supporting process development trials
- Championing safety in the development of new processes and equipment
Form Energy manufactures long-duration iron-air battery systems for grid-scale energy storage. 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." The company is scaling rapidly with signed contracts from leading US electric utilities and production underway at their first high-volume manufacturing facility.
The role is based at Form Factory 1 in Weirton, WV, a 550,000-square-foot facility serving as the hub for high-volume battery production. Relocation assistance is available. Form Energy offers competitive salaries, stock options, comprehensive benefits including 100% medical/dental/vision premiums for employees, at least 12 weeks paid parental leave, and generous vacation policies.
Requirements:
- 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 proven ability to lead cross-functional technical initiatives independently
