Staff Controls Engineer, Robotics & Vision

Role Description

As a Staff Controls Engineer on the Robotics & Vision team, you will step into a high-impact technical leadership role. You will own the design, development, and deployment of novel automation equipment used to manufacture our revolutionary Iron-Air batteries. Reporting to our Senior Controls Engineering Manager, you will serve as a pillar of a rapidly growing Manufacturing Control and Execution Systems team.

• Technical Leadership: Act as the technical lead on multiple concurrent Robotics & Vision projects, collaborating closely with Automation, E&I, and SCADA teams to deliver complex systems on time and within budget.
• Mentor & Guide: Share your wealth of knowledge to technically and professionally mentor less experienced robotics and vision controls engineers.
• Vendor Partnership: Collaborate directly with equipment vendors to ensure they meet Form Energy’s rigorous equipment standards. You will lead Factory Acceptance Testing (FAT) at vendor sites and Site Acceptance Testing (SAT) at Form Factory 1.
• Hands-on Innovation: Develop, test, and program advanced robotics and vision systems, integrating them seamlessly with PLCs, SCADA, and MES layers. This includes programming and troubleshooting MES data transactions within PLC programs.
• Continuous Improvement & Support: Serve as an advanced escalation point for our sustaining, production operations, and maintenance teams. You’ll troubleshoot complex robotics, vision, and electrical issues to maximize throughput and ensure top-tier safety. (Note: This role includes a rotating on-call responsibility for off-hour high-level escalations).

What You'll Bring

• Experience: 8+ years of hands-on engineering experience working deeply with robotic systems in a manufacturing environment.
• Education: Bachelor’s degree in Electrical, Controls, or Mechatronics Engineering, or equivalent hands-on industry experience.
• Advanced PLC Programming: Independence in programming and troubleshooting within Siemens TIA-Portal and Rockwell Studio 5000, including PLC product tracking and handshake/data programming.
• Robotics Mastery: Advanced proficiency in FANUC and FANUC ROBOGUIDE (you should be comfortable training others on these platforms).
• Vision Systems: Expertise in Keyence and Cognex Barcode Scanners, Inspection systems, and Position applications (ability to train others required).
• Functional Safety: Deep familiarity with Functional Safety systems. You can independently review electrical hardware and programming, train others on FANUC DCS Programming, and handle Siemens ProfiSafe and Rockwell CIP Safety programming (with minimal supervision).
• Electrical & Diagnostic Skills: Ability to independently read, interpret, and redline complex electrical schematics to troubleshoot industrial hardware.
• Tools: Independent execution using iba and Octoplant.
• Nice To Have: Familiarity with Beckhoff TwinCat. Experience with SCADA/HMI platforms like Ignition Perspective, Siemens WinCC, or Rockwell FTView ME. Knowledge of OT Networks (configuring Siemens Scalance Managed Network Switches). Design experience using AutoCAD Electrical or SolidWorks. Experience with IPC/Panel PC setup and control panel fabrication.

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.