Manufacturing Engineer, Welding

Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company. We’re 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’re giving clean energy a whole new form!

In recent years, Form Energy has earned a number of accolades, including being named 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”. We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand.

We have signed contracts with leading electric utilities across the United States and production of our iron‑air batteries is underway at our first high‑volume manufacturing facility in West Virginia.

Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing - might be 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, our team is determined to deliver on our mission and transform the energy landscape for the better.

We are seeking a Staff Manufacturing Engineer specializing in welding and bonding processes to act as a Joining Specialist. In this position, you will be part of our Advanced Manufacturing Engineering team responsible for developing, optimizing, and scaling new manufacturing processes for Form Energy’s Iron‑Air multi‑day battery.

As a Joining Specialist, you will play a crucial role in defining the processes used to seal our cell vessels, create electrical interconnects, and assemble auxiliary systems. You will focus on developing highly capable processes that enable the product design to meet our cost and performance targets while ensuring the stability of novel manufacturing processes. Your work will make a significant and daily impact on our mission to revolutionize grid reliability and sustainability.

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

• Lead the development and optimization of joining processes, such as welding (metal and plastic), and adhesives bonding for novel battery manufacturing technologies.
• Partner closely with our equipment team to design, install, and commission equipment for our first‑of‑kind manufacturing processes.
• Collaborate with the product design team, R&D, quality, and supply chain, to translate product requirements into process and testing requirements.
• Develop novel test methods to evaluate products in real time during production.
• Provide data‑driven feedback to the Design team to simplify product design for improved manufacturability (DFM).
• Ensure highly capable processes are developed and demonstrated ahead of detailed equipment design. Measure process capability and evaluate limit samples through bench top testing.
• Conduct process capability studies, utilize statistical analysis tools (e.g., Design of Experiments). Lead troubleshooting efforts to identify root causes of manufacturing issues and implement corrective actions to prevent recurrence while optimizing processes.
• Develop and maintain PFMEA, process specifications, measurement systems GR&R, control plans, and quality inspection methods (incoming, outgoing, and in‑process).
• Demonstrate ownership and accountability for novel joining processes from concept to high volume production in a fast‑paced environment.
• Mentor, guide, and support junior team members with your expertise and practical experience.
• Drive yield, quality, and performance through a data‑driven approach.

• Bachelor’s degree in Chemical Engineering, Materials Science, Mechanical…