Senior Director, Advanced Manufacturing, Assembly

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. Trial production of our iron-air batteries has already begun, and 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 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

Form Energy is pioneering a new class of battery technology to transform the grid. We are seeking a visionary manufacturing engineering leader to develop, industrialize, and scale our battery assembly manufacturing processes and equipment—spanning cell, module, and full system integration.

You will lead a multidisciplinary team that industrializes our novel iron-air technology—developing robust processes and automation assembly equipment, from pilot to high volume. You’ll treat the factory as a product, working in tight collaboration with product design and operations to deliver scalable, cost-effective, and highly capable manufacturing systems.

This is a critical leadership role at the intersection of product, process, and equipment engineering, requiring first-principles thinking and operational rigor.

This opportunity is based out of Form Factory 1 in Weirton, WV. Relocation assistance is available.

What you'll do:

• Build and lead a world-class team of multidisciplinary engineers focused on assembly process and equipment development and scale up.

• Set the vision and operating system for the advanced manufacturing organization —driving a culture of excellence, urgency, data-driven iteration, and technical rigor.

• Own and drive the end-to-end roadmap for process development, DFM, equipment design, sourcing, and deployment across all levels of assembly.

• Translate product architecture into scalable processes for joining, sealing, precision assembly, electrical/mechanical testing, and integration.

• Identify and mitigate risk proactively through PFMEA, DFM, capable inspection strategies, and robust control plans.

• Design, source, and commission assembly lines at multiple scales—from prototyping lines to fully automated, high-throughput production.

• Lead equipment supplier strategy, authoring specifications and setting Form Energy standards for automation, controls, safety, ergonomics, and maintainability.

• Demonstrate process readiness before handoff to operations: conduct burst builds, perform process capability studies, GR&R validation, and implement SPC for critical features.

• Drive lean innovation: simplify designs, eliminate non-value-add steps, and reduce cost and complexity over successive iterations (“the best process is no process, the best part is no part”).

• Drive capable process yield, quality, and throughput through structured experimentation, root-cause analysis, and fast deployment of corrective actions.

• Own factory capacity modeling and collaborate cross-functionally to inform make/buy decisions, tooling strategy, and production scaling plans.

• Ensure cross-functional alignment with internal and external partners to hit technical milestones, cost targets, and production readiness goals.

What you'll bring:

• 10+ years of experi