Staff Process Engineer, Cathode

Are you ready to build America’s clean energy future with the team that will deliver? Form Energy is an American energy technology and manufacturing company. We are pioneering a new class of iron-air batteries to enable our electric grid to run on renewable, reliable, and affordable energy, every day of the year. 

Form Energy has been recognized by TIME as “One of the Best Inventions of 2023” for its battery technology and by MIT Technology Review as a “Top Climate Tech Company to Watch”. We are making rapid progress on our mission of delivering energy storage for a better world, and are growing just as rapidly to meet demand. Our team has more than doubled in size in the past year, and continues to expand every day. We have signed contracts with leading electric utilities across the United States. Pilot production of our iron-air batteries has already begun, and later this year, production will take off to high volumes at our new factory in West Virginia. 

Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And right now might be the most exciting moment in the company’s history to join. We are assembling a team of some of the most talented and motivated 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 seeking Staff Process Engineers to join our world-class Cathode Process 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 Staff Process Engineer, you will have a direct impact on the design and operations of the equipment that creates our Cathode. You will develop and own trials, analyze data, and identify key process inputs to analytically develop new processes and scale our production.  You will also oversee the automation of quality and verification standards. Your expertise with process scale up and rapid troubleshooting will enable you to make large contributions in our fast-paced environment. No problem is too big or small for our team, which allows us to move quickly to develop our cutting edge technology! This is a fantastic opportunity to join an early-stage cleantech company with a direct impact on the nature of energy storage and renewables. 

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.

What you'll do:

• Partner closely with our Manufacturing Equipment Team to design, build, install, and run processes on first-of-kind manufacturing equipment 

• Prioritize safety while scaling initial process designs to full production volume 

• Define and implement metrics and use quality data to define good process windows

• Own process trials and make data-driven decisions to scale up and improve quality in real time during production

• Commission and own novel processes in a fast-paced manufacturing environment; including acceptance testing while taking into consideration tight timelines 

• Work with and act as a technical lead to a diverse range of teams inside and outside the company to achieve major manufacturing milestones, such as launching revolutionary production methods and capabilities

• Mentor, guide, and support team members with your expertise and practical experience

What you'll bring:

• 7+ years of experience in a fast-paced manufacturing or production environment, ideally in NPI or scale–up 

• Expertise with medium to large equipment and desire to roll up your sleeves and fill the gaps where necessary

• Strong experience with statistical methods for making process development decisions (Statistical Process Control / SPC) using JMP, Minitab or equivalent

• Demonstrated experience owning manufacturing processes and showing accountability for their quality, throughput, yield, and overall success

• Expertise in PFMEAs, factory acceptance testing, and process validation

• Ability to define standards for authoring process, safety, and quality documentation for best-in-class practices, as well as excellent communication and organizational skills 

• Direct experience with roll to roll manufacturing, lamination, calendaring, adhesion, epoxy, plastic welding, powder handling or similar is required 

• Bachel