Process Engineer

Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company that is revolutionizing energy storage with cost‑effective, multi‑day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what’s possible, we are giving clean energy a whole new form.

Working for Form Energy is more than just a job; it’s a chance to be part of something extraordinary. As we scale up battery manufacturing, this is the most exciting moment in the company’s history to join. We are assembling a team of highly talented and driven individuals across the country, driven by our core values of humanity, excellence, and creativity.

Form Energy is hiring a Staff Process Engineer to join our world‑class anode engineering team. Our team is responsible for designing, developing, and scaling cutting‑edge electrode manufacturing processes for Form Energy’s Iron‑Air multi‑day battery.

As a Staff Process Engineer, you will be at the forefront of translating novel research into efficient, high‑quality manufacturing processes. Your expertise with process scaling and rapid troubleshooting will have a direct impact on the design and operations of the equipment that creates Form’s Iron Anode. You will design experimental trials, identify and optimize key process inputs, analyze data and present technical reports, all to facilitate the smooth integration of new processes, equipment, and materials.

No problem is too big or small for our team, which allows us to move quickly to develop our cutting‑edge technology.

This role will be located at Form Factory 1 in Weirton, WV, just a short drive outside of Pittsburgh, PA. Relocation assistance is available.

• Partner closely with our Manufacturing Equipment Team to give manufacturing process design feedback, install and commission, and run processes on first‑of‑kind manufacturing equipment.
• Commission and qualify new processes using structured experimentation and risk‑based decision‑making.
• Perform equipment and process capability studies and implement SPC ready strategies to ensure consistent quality at scale and effective handoffs to operations.
• Drive continuous improvement through root cause analysis, statistical analysis, and hands‑on testing.
• Mentor and support technicians and junior engineers during process development, scale‑up, and issue resolution.
• Collaborate with cross‑functional teams to integrate materials, equipment, process design with a strong focus on safety and manufacturability.

• 7+ years of experience with process engineering in a pilot line or fast‑paced manufacturing environment, such as NPI or scale‑up.
• Some proficiency in experimental design, statistical analysis (JMP or Minitab) and structured problem solving.
• Track record of scaling processes from concept to production with hands‑on ownership of critical process parameters.
• Comfortable navigating ambiguity and working across equipment, materials, operations, and quality.
• Excellent documentation, collaboration, organization, and communication skills, especially in cross‑functional or multidisciplinary settings.
• Bachelor’s degree in Mechanical Engineering, Materials Science, or Manufacturing Engineering.
• Experience with powder processing, thermal treatments, welding, or metallurgical systems is a strong bonus.

Humanity is a cornerstone of Form Energy’s culture, and we make sure our compensation and benefits reflect that. Form Energy offers competitive salaries, stock options, and a holistic benefits package to ensure all employees have what they need to thrive while working here.

When it comes to you and your family’s health, we cover 100% of medical, dental, and vision premiums for full‑time employees – and 80% of healthcare premiums for dependents. This starts from day one. We also offer at least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents) and generous vacation policies to give employees time to recharge when needed.

To build America’s energy future, we need everyone at the table. We are proud to be an equal opportunity employer and encourage candidates from all backgrounds to apply to our open jobs.

If you may require reasonable accommodations to participate in our interview process, please contact  Requests for accommodations will be treated with discretion.

Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.