Senior Quality Engineer, Pack

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.

Role Description

We are hiring a Senior Quality Engineer to serve as the quality engineering owner for our Pack assembly area. You will develop and own 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 a manual assembly environment. This is a hands-on individual contributor role spanning the full product development lifecycle — from R&D validation through pilot and high-volume production. You will be a critical member of Form Energy's Quality Team, ensuring pack assemblies consistently meet customer and internal requirements. Relocation assistance is available.

What you'll do:

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

• Lead change management and support execution of process development experiments in the pack assembly area

• 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 reduce variation in manual assembly processes

• Lead non-conforming material control activities for pack assemblies and sub-components

• Develop, qualify, and maintain manual inspection methods and visual inspection standards for pack assembly operations

• Define GD&T-based inspection plans and ensure dimensional conformance of structural and mechanical components

• Develop test plans and inspection procedures for electronics components — including PCBs, connectors, sensors, and wiring harnesses — within the pack

What you'll bring:

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

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Materials Science, 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), etc.

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

• Ability to manage, synthesize, and interpret data from manual assembly processes

• Proficiency in GD&T (Geometric Dimensioning and Tolerancing) and experience defining dimensional inspection plans for structural mechanical components

• Experience with electronics component inspection and testing — developing functional test methods and in-process inspection criteria for PCBs, connec