Staff Process Development Engineer
About the role
Form Energy is an American manufacturing and energy technology company revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. The company has been recognized by TIME as a “Best Invention”, MIT Technology Review as a “Top Climate Tech Company To Watch”, and Fast Company as “One of the Next Big Things In Tech”. Form Energy is scaling up battery manufacturing at its first high-volume facility in Weirton, WV (Form Factory 1), with relocation assistance available. The Staff Process Development Engineer will lead the invention and scale‑up of new manufacturing processes for the Gas Diffusion Electrode (GDE), working within the GDE Advanced Manufacturing team to move from early feasibility through pilot‑line qualification in collaboration with Materials Science, Product Development, Manufacturing Engineering, and Quality teams.
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 and stock options
- Holistic benefits package
- 100% of medical, dental, and vision premiums covered for full‑time employees (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