Staff Materials Engineer

Form Energy · Weirton, WV · 2 days ago

On-siteFull-time

About the role

Form Energy is hiring a Staff Materials Engineer to join our Air Electrode Engineering team and play a critical role in designing and validating key components in our Iron-Air Batteries. Reporting to the Manager of Air Electrode Engineering, you will be responsible for ensuring the performance, reliability, and scalability of electrode designs produced on our mass manufacturing lines, making significant contributions to the operational success of our Iron-Air Battery as a whole. We are looking for someone who has hands-on experience in materials design and characterization, a proactive approach to problem-solving, and a track record of solving challenges in fast-paced manufacturing environments. Relocation assistance is available.

Responsibilities

Partner with vendors, manufacturing engineers, quality engineers, and process engineers to transition materials and designs from the prototype stage to high-volume production.
Own the design and validation of key electrode materials, utilizing statistical methods to determine product specifications that balance performance, cost, and manufacturability criteria.
Drive on-the-ground, hands-on design efforts including prototyping, failure analysis, spec-setting, and material evaluation.
Develop and implement novel material characterization techniques to enable evaluation and quality control of product manufactured on high-volume production lines.
Independently apply sound engineering judgment to recommend disposition decisions on materials and electrodes coming off high-volume production lines, weighing design, performance, and reliability requirements against manufacturing realities.

Requirements

Bachelor’s Degree and 7+ years of experience in materials science, materials engineering or a related field.
3+ years of hands-on product development experience navigating the transition of materials from R&D to high-volume manufacturing environments, with fluency in Design for Manufacturing (DFM) and how manufacturing constraints shape design decisions.
Demonstrated experience planning rigorous engineering trials via Design of Experiments (DOE) and interpreting complex experimental datasets utilizing statistical tools such as JMP or Minitab.
Demonstrated experience using engineering tools such as FMEA and RCA to track and mitigate risks.
Clear verbal and written communication skills, with the ability to influence cross-functional stakeholders and summarize complex technical conclusions for both technical and non-technical audiences.
Dedication to pragmatic problem-solving, a growth mindset, and a capacity for operating effectively amid complexity within a fast-paced organization.
Willingness to travel domestically up to 10% of the time to support project execution across different sites.

Location

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