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 our Gas Diffusion Electrode (GDE). As part of our GDE Advanced Manufacturing team, you will lead new process development for GDE fabrication — from early feasibility through pilot-line qualification — in collaboration with Materials Science, Product Development, Manufacturing Engineering, and Quality teams. This is an exciting opportunity to help shape and be part of the growth of a fast-moving company with breakthrough technology and an incredible mission! Relocation assistance is available. 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.
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
- Demonstrated experience designing and executing experiments and translating results into robust, production-ready processes
- Hands-on experience with material processing equipment and process characterization techniques
- Experience using statistical methods to guide process development decisions
- 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
Benefits
- Competitive salaries
- Stock options
- Holistic benefits package
- 100% of medical, dental, and vision premiums covered for full-time employees (starting day one)
- 80% of healthcare premiums covered for dependents
- At least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents)
- Generous vacation policies
- Relocation assistance available