Staff Manufacturing Engineer, Thermoplastics

Are you ready to rise to the challenge of climate change with the team that will deliver? Form Energy is a U.S. technology and manufacturing company that is developing and commercializing pioneering energy storage technologies to enable the electric grid to run on 100% renewable energy, every day of the year.

Supported by leading investors such as Breakthrough Energy Ventures, ArcelorMittal, TPG Rise, MIT’s The Engine, and others, we share a common belief that low-cost, multi-day energy storage is the key to enable tomorrow’s zero carbon electric grid. Driven by our core values of humanity, excellence, and creativity, we are deeply motivated and inspired to create a better world. We need talented, hardworking individuals who share our goal of tackling the challenge of climate change. Do you want to work with us today to build a better tomorrow? 

Role Description

We are seeking a highly skilled and experienced Staff Manufacturing Engineer specializing in thermoplastic transformation processes to join our dynamic team. You will play a crucial role in optimizing and enhancing our thermoplastic manufacturing operations, with a focus on injection molding, extrusion, or thermoforming processes. You will have a strong background in thermoplastic materials, processing technologies, tooling design, and quality control methods. Additionally, you should possess excellent problem-solving abilities and a proven track record of driving continuous improvement initiatives within a manufacturing environment.

This role will be located at Form Factory 1 in Weirton, WV, which is just a short drive outside of Pittsburgh, PA

What you'll do:

• Lead process design , deployment and optimization efforts for thermoplastic transformation processes such as injection molding, extrusion, or thermoforming, to improve productivity, quality, and efficiency.

• Develop and implement manufacturing processes, equipment and procedures for the production of thermoplastic components, ensuring compliance with quality standards and specifications.

• Collaborate with cross-functional teams including design engineering, tooling engineering / vendors, and quality assurance to support the development and launch of Form Energy new products.

• Conduct feasibility studies and risk assessments to evaluate new technologies, materials, and equipment for potential integration into manufacturing processes.

• Design and optimize tooling and fixtures for thermoplastic transformation processes, utilizing CAD software and simulation tools as needed.

• Establish and maintain robust process monitoring and control systems to ensure consistent and reliable production of thermoplastic components.

• Identify opportunities for cost reduction and waste minimization through process improvements and lean manufacturing principles.

• Lead root cause analysis and corrective action efforts to address process deviations, non-conformities, and quality issues.

• Provide technical support and training to production personnel to ensure adherence to standard operating procedures and best practices.

• Stay current with advancements in thermoplastic materials, processing technologies, and industry trends, and leverage this knowledge to drive innovation and competitiveness.

What you'll bring:

• 7+ years of experience in manufacturing engineering, with a focus on thermoplastic transformation processes such as injection molding, extrusion, or thermoforming.

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Polymer Science, or a related field; advanced degree preferred.

• Strong understanding of thermoplastic materials, rheology, and processing parameters.

• Proficiency in CAD software for tooling design and simulation (e.g., SolidWorks, Moldflow).

• Experience with statistical analysis tools and methodologies for process optimization (e.g., Design of Experiments, Six Sigma).

• Knowledge of quality management systems and standards (e.g., ISO 9001, IATF 16949).

• Ability to troubleshoot complex manufacturing issues.

• Strong communication and interpersonal skills, with the ability to collaborate effectively with cross-functional teams.

• Proven track record of driving continuous improvement initiatives and achieving measurable results.

• Experience in the automotive, consumer goods, or medical device industries preferred.

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Humanity is a cornerstone of Form Energy’s culture, and we make sure our compensation and benefit