Staff Mechanical Engineer, High-Voltage Design

About the role

Form Energy’s Electromechanical team is seeking a staff-level technical lead Electro-mechanical Engineer to drive the requirements, design, simulation, and testing of our Gen 2 and beyond power systems for clean energy delivery from batteries to the grid. You will be responsible for designing electro-mechanical sub-assemblies that will deliver power and control signals to various auxiliary systems within the battery enclosure. You will take designs from concept to production in a fast-paced environment while ensuring quality and reliability through rigorous tests. This role requires collaboration with various engineering teams, making it an exciting opportunity to contribute to cutting-edge technology at a dynamic company with a remarkable mission.

Responsibilities

• Provide technical leadership and mentorship within a multidisciplinary engineering team, fostering growth and problem-solving skills across team members
• Own the electromechanical design of Form’s battery products, including high voltage distribution (busbars and cables), isolation, grounding, harnessing, connectors, over-molded bussing, plastic and metal enclosures for various PCBA and electrical assemblies, and safety and interlocks (contactor, fuses, etc.)
• Design and optimize high voltage joints for reliability and performance (bolted, welded, etc.)
• Address challenges related to electronics packaging, encompassing tasks such as electrical isolation, sealing, thermal regulation, interconnection, and shock and vibration mitigation
• Lead RCAs and cross-functional interface design
• Perform mechanical design analysis including thermal, structural, design for assembly, and design for test
• Own the design from conception through all iterations to mass-production
• Create drawing packages and manufacturing instructions for parts and assemblies
• Design and develop electromechanical and electrical systems in support of test stand safety, improvements, and simplification

Requirements

• A degree in Mechanical/Mechatronics Engineering or a related field; bachelor's with 6+ years, or master's with 5+ years of relevant experience developing medium to high-volume products
• Proven experience with electrical and mechanical design and proficiency in CAD (SolidWorks, NX, etc.)
• Expertise in cost modeling, multi-physics simulations (e.g., thermal, CFD, structural), and optimizations, with the ability to navigate system-level trade-offs and integrate them into architecture studies
• Strong mechanical and electrical engineering fundamentals, GD&T, and first principles hand calculations
• Direct experience with high-volume manufacturing, fabrication, and prototyping techniques; experience with tight-tolerance, component design for harsh environments, DFM/DFA
• Solid understanding of power distribution, electrical circuits, and protection devices
• Superb understanding of creepage and clearance analysis and standards (e.g., IEC, UL, etc.)
• Ability to model resistive losses, run current density analysis to optimize busbar geometry and sizing to meet system performance and mass requirements

Preferred Qualifications

• Familiar with electrical standards (NEC); experience with battery and power conversion standards (UL9540, UL1741) a plus
• Leadership, the ability to mentor, and well-developed communication, collaboration, and engagement skills working with a variety of teams and stakeholders

Benefits

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

Pay

Compensation Range: $147,959 - $194,218