Lead Process Engineer, Automation

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.

Feeling energized to make a meaningful impact on the world? Then keep reading - you've come to the right place.

Job Description

We're hiring a Lead (Staff) Process Engineer within our growing Operations Engineering team. In this role, you will serve as a primary technical lead for the automated systems and equipment strategies required to ramp production of our iron air battery. You will own the operation of complex robotic cells and automated hardware, driving technical decisions that eliminate manufacturing bottlenecks and ensure long-term equipment reliability.

By continuously improving standards for automation and precision control, you will ensure our production environment delivers a high volume of top quality products. Your leadership will be the cornerstone in transforming advanced battery technology into a world-class, automated manufacturing reality that secures global energy reliability.

What You'll Do

* Own and improve semi-manual and automated manufacturing processes for modular products.

* Define and implement OEE and equipment performance metrics to identify loss drivers and prioritize improvement work.

* Collaborate with product design and process development engineering to provide DFM/DFA feedback, ensuring optimization for fully-automated, high-speed manufacturing.

* Drive cross-functional alignment with controls and equipment teams to integrate automation solutions such as torque tools, lift devices, vision checks, interlocks, and other instrumentation.

* Lead root-cause analysis of assembly and quality issues, turning findings into durable automation improvements that ensure safe and repeatable production.

* Support production ramp and sustaining operations, stabilizing builds and reducing variation across shifts

* Mentor and guide multidisciplinary engineering teams, fostering a culture of technical excellence in automated system design and pragmatic problem-solving.

What You'll Bring

* Bachelor's degree in Mechanical Engineering, Electrical Engineering, Robotics, Controls, or a related discipline and 7+ years of relevant experience.

* Deep technical understanding of semi-manual and automated assembly processes for complex systems

* Demonstrated expertise with Fanuc Robotics and Siemens PLCs or similar.

* Extensive experience developing assembly methods, tooling, fixtures, and work instructions in an automated production environment.

* Proven track record of providing DFM/DFA feedback to product design and process development teams, influencing part design, interfaces, tolerances, and fastening strategies to improve manufacturability.

* Strong problem-solving skills with the ability to identify and address process, design,…