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Form Energy is hiring a Staff Process Engineer to lead the manufacturing process for a high-volume cathode assembly line at their flagship facility in Weirton, WV. You will own the process from early conceptual stages through production ramp, including line capacity modeling, PFMEA generation, proof-of-concept testing, vendor selection, and commissioning.
Key responsibilities include:
- Serve as process engineering line lead, owning the manufacturing process for a complex multi-step assembly line from concept through production ramp
- Develop line models to validate throughput, cycle time, staffing, and capacity assumptions before equipment build
- Engage with design engineering early to influence product and process requirements for manufacturability; generate and maintain PFMEAs to drive design and process decisions
- Support development of detailed user requirement specifications (URS) and factory/site acceptance testing plans (FAT/SAT); manage vendors and integrators through equipment design, build, delivery, and commissioning
- Lead proof-of-principle testing to validate equipment and process design choices early, with support from internal process development and mechanical design resources
- Onboard and direct a team of process development and operations engineers onto the line at FAT; generate clear documentation, deliverables, and work breakdown structures
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" and MIT Technology Review as a "Top Climate Tech Company To Watch." The Weirton facility is a 550,000-square-foot hub for high-volume battery production. Relocation assistance is available.
REQUIREMENTS:
- 4+ years of experience in manufacturing in a process engineering or operations role, ideally with high-volume assembly processes
- Demonstrated experience leading a process line from early design through commissioning and ramp, including line modeling and capacity planning
- Strong track record generating PFMEAs and applying them to drive design and process decisions
- Experience across equipment procurement, vendor management, and commissioning (URS, FAT/SAT), with proven project management and organization skills
- Hands-on experience with laser welding processes and with vision and high-volume in-line inspection systems strongly preferred
- Solid technical background with ability to communicate and collaborate effectively across disciplines
- Degree in Mechanical or Manufacturing Engineering
