Staff Process Development Engineer

About the role

Form Energy is hiring a Staff Process Development Engineer to lead the invention and scale‑up of new manufacturing processes for the Gas Diffusion Electrode (GDE). As part of the GDE Advanced Manufacturing team, you will lead new process development for GDE fabrication from early feasibility through pilot‑line qualification, collaborating with Materials Science, Product Development, Manufacturing Engineering, and Quality teams. You will own the manufacturing process for a first‑of‑its‑kind iron‑air battery at a high‑volume facility in Weirton, WV, helping to shape the growth of a fast‑moving company with breakthrough technology and an incredible mission.

Responsibilities

• Lead development of new and next‑generation GDE manufacturing processes, from bench‑scale concept through pilot‑line qualification
• Design and execute experiments to characterize and optimize process parameters against quality, throughput, and performance targets
• Partner with Materials Science and Product Development to translate new material formulations into manufacturable, scalable processes
• Drive root‑cause investigations for process and quality excursions, translating experimental data into corrective actions
• Define process specifications and control plans, and own technical handoff of new processes to Manufacturing Engineering for scale‑up
• Train and mentor engineers and technicians supporting process development trials
• Be a champion for safety in the development of new processes and equipment

Requirements

• 7+ years of experience in process development or manufacturing engineering, ideally in batteries, electrodes, or advanced materials manufacturing
• Hands‑on experience with material processing equipment and process characterization techniques
• Experience using statistical methods to guide process development decisions

Qualifications

• Bachelor’s degree in Materials Science, Mechanical Engineering, Chemical Engineering, or a related field
• Excellent communication and organizational skills, with a proven ability to lead cross‑functional technical initiatives independently

Skills

• Process characterization techniques
• Statistical analysis
• Cross‑functional team leadership
• Safety advocacy
• Technical training and mentoring

Benefits

• Competitive salary
• Equity/stock options
• Relocation assistance
• 100% of medical, dental, and vision premiums covered for full‑time employees (80% for dependents)
• At least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents)
• Generous vacation policies

Schedule

Full-time