Senior Quality EngineerQuality * Weirton, WV On-site

Overview

Are you ready to build America's energy future? Form Energy is an American manufacturing and energy technology company focused on cost-effective, multi-day energy storage to keep the electric grid secure and reliable during extended stress. We are growing rapidly as we scale up battery manufacturing and expand our impact in the energy landscape.

We are hiring a Senior Quality Engineer to serve as the quality engineering owner for our electrode manufacturing area. You will develop quality processes and methodologies, lead cross-functional teams, and partner with Design Engineering, Manufacturing Engineering, Suppliers, and Operations to address quality, reliability, and manufacturability challenges across the electrode production process. This is a hands-on individual contributor role covering the full product development lifecycle—from early R&D and validation testing through pilot builds and high-volume production.

You will be a key contributor to Form Energy's Quality Team, ensuring that electrode products consistently meet customer and internal requirements. Relocation assistance is available.

• Own and drive quality processes and documentation for electrode manufacturing, including Control Plans, PFMEAs, and inspection/test methods

• Lead change management and support execution of process development experiments across batch powder mixing, thermoplastic polymer processing, heat treatment, epoxy curing, and continuous web handling operations

• Regularly review and revise PFMEAs and Control Plans to reflect process changes and lessons learned

• Lead identification and resolution of manufacturing quality issues, including root cause analysis and corrective actions

• Drive continuous improvement activities in partnership with Design/Manufacturing Engineering and external Suppliers

• Lead Statistical Process Control (SPC) activities and apply critical thinking to systematically reduce variation across electrode manufacturing unit operations

• Lead non-conforming material control activities for electrode materials and sub-components

• Develop and apply material characterization and testing protocols, including TGA, DSC, and powder characterization methods, to support process control and qualification

• Collaborate proactively with process and product development teams to identify, assess, and mitigate quality risks before they reach production

• 3-10 years of quality engineering experience in a manufacturing environment

• Bachelor's degree in Materials Science, Chemical Engineering, Mechanical Engineering, Electrical Engineering, or a related field; advanced degree a plus

• Solid experience with SPC, PFMEAs, and Control Plans

• Strong aptitude with electronic test and measurement systems

• Proficiency in reading and interpreting mechanical drawings and wiring diagrams

• Structured problem-solving (8D) and strong statistical skills including DOE, Process Capability (Cpk, Ppk)

• Proficiency with data analysis tools such as JMP, R, Minitab, or equivalent

• Ability to manage, synthesize, and interpret complex data sets

• Familiarity with electrode manufacturing processes such as batch powder mixing, thermoplastic polymer processing, metal heat treatment, epoxy curing, or web handling/continuous manufacturing

• Experience with materials characterization techniques such as TGA, DSC, or powder characterization (particle size distribution, flowability) is a plus

This role is based at Form Factory 1 in Weirton, WV. 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 offer competitive salaries, stock options, and a holistic benefits package. We aim to support the health and well-being of our employees and their families from day one.

We are 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.