Senior Controls Engineer

About the role

We are looking for a Senior Controls Engineer to join the Manufacturing Control and Execution Systems - Automation team. In this role you will be responsible for design, development, and deployment of novel equipment used to manufacture Form Energy’s Iron-Air battery. This role offers an exciting opportunity to be part of a mission critical team that owns control and execution systems throughout their lifecycle including design, development, deployment, and sustaining.

Reporting to our Controls Engineering Manager, Automation, you will be part of a quickly-growing manufacturing control and execution systems team. You will have opportunities in this role to lead efforts to design and develop innovative solutions, as we work together to deploy manufacturing equipment control and execution systems and to make continuous improvements to our equipment, processes, and systems.

Responsibilities

• Lead the design, programming, and deployment of complex industrial control systems (PLC/HMI/SCADA) for novel battery manufacturing equipment.
• Serve as the technical lead for automation projects, coordinating cross-functionally with Robotics, Vision, and SCADA teams to ensure systems meet technical requirements on schedule.
• Develop and test PLC-to-MES data transactions and tracking handshakes to ensure seamless manufacturing execution and data integrity.
• Partner with external equipment vendors to enforce Form Energy standards, conducting Factory and Site Acceptance Testing (FAT/SAT).
• Provide expert-level electrical and controls support to resolve escalated production issues, minimizing downtime and improving process throughput.
• Mentor and provide technical guidance to junior engineers, fostering a culture of excellence and high performance.
• Drive continuous improvement initiatives by utilizing feedback from production and maintenance teams to optimize system reliability and safety.
• Participate in a rotating on-call schedule to provide high-level troubleshooting support for mission-critical manufacturing operations.

Requirements

• Bachelor’s degree in Electrical Engineering, Mechatronics, or a related field, or equivalent practical experience.
• 6+ years of applied experience designing and troubleshooting industrial control systems in a high-volume manufacturing environment.
• Advanced PLC proficiency in Siemens TIA-Portal and Rockwell Studio 5000, with the ability to program and execute independently.
• Practical experience with SCADA and HMI platforms, specifically Ignition Perspective, Siemens WinCC, or Rockwell FTView.
• Strong technical foundation in functional safety programming, including ProfiSafe and CIP Safety protocols.
• Expertise in reading, interpreting, and redlining complex electrical schematics and using data tools like iba or Octoplant for system analysis.
• Familiarity with integrating vision systems and barcode scanners, such as Keyence or Cognex, into automated workflows.
• Excellent technical communication skills and the ability to translate complex controls concepts for diverse audiences.
• Pragmatic problem-solving skills and a commitment to intellectual rigor when tackling first-of-a-kind automation challenges.
• Thriving on complexity and maintaining a low-ego, collaborative approach within a fast-paced, mission-driven team.
• Intellectual curiosity and a drive to stay at the forefront of industrial automation and control technology.

Where you'll work

This role is based at Form Factory 1 in Weirton, WV—an easy commute from the city of Pittsburgh, PA. This 550,000-square-foot facility is our hub for high-volume battery production and a leader in the new era of American energy manufacturing. Relocation assistance is available.

Benefits

• Competitive salaries and stock options.
• 100% coverage of medical, dental, and vision premiums for full-time employees starting from day one, and 80% coverage for dependents.
• At least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents).
• Generous vacation policies.