Senior Process Engineer, Powder Mixing

Senior Process Engineer – Powder Mixing

Form Energy is hiring a Senior Process Engineer – Powder Mixing to join our world-class 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 Senior Process Engineer, you will lead the development and optimization of powder mixing operations that are fundamental to the performance and reliability of our electrodes. Your expertise in powder handling, mixing, and scale-up will directly influence the quality, consistency, and throughput of our cathode manufacturing line. You will design and execute experiments, analyze process data, and collaborate with equipment and operations teams to ensure robust and safe scale-up of our mixing systems.

This is a unique opportunity to take ownership of a critical process area while shaping the future of a transformative energy storage technology.

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.

• Develop, scale, and optimize powder mixing processes for high-volume electrode manufacturing.
• Define process requirements and partner with equipment engineers to design, specify, and qualify mixing systems.
• Lead experimental trials on current manufacturing lines to establish process windows, improve quality, and increase throughput.
• Scale-up novel test methods for powder characterization and own the data analysis to evaluate product quality.
• Be a champion for safety while scaling initial process designs to full production volume.

• 5+ years of experience with powder mixing, blending, or related powder handling processes in a manufacturing or pilot environment.
• Demonstrated ability to scale powder processes from lab to production, with a track record of solving complex technical challenges.
• Hands-on experience with industrial mixers (e.g., high-shear, plow, or ribbon mixers), powder handling equipment, and/or material characterization (particle size, shape, surface area, flowability).
• Strong foundation in statistical process control methods, and data-driven decision-making.
• Excellent communication and organizational skills, with experience writing process, safety, and quality documentation.
• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a related field.

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. Relocation assistance is available.

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.