Staff Thermal Simulation Engineer

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

As a Staff Simulation Engineer specializing in Computational Fluid Dynamics (CFD) and Thermal Systems, you will play a critical role in bringing Form Energy's multi-day energy storage systems from R&D and pilot stages to full-scale commercial utility deployment. You will own the thermal-fluid architectural strategy, physics-based modeling framework, and multi-scale simulation methodologies for our 100-hour iron-air battery systems. Resolving complex, multi-variable issues across electrical, mechanical, and electrochemical boundaries, you will establish the predictive modeling standards required to ensure the ultimate safety, durability, and commercial readiness of our technology. Your technical leadership will directly enable the optimization of system-level thermal management architectures, ensuring predictable operation and long-term grid stability. Relocation assistance is available.

What you'll do:

• Architect high-fidelity computational fluid dynamics (CFD) and transient thermal modeling strategies across multiple physical scales, spanning from micro-scale electrochemical cell fields to macro-scale containerized systems.

• Validate and anchor numerical physics-based models against empirical data, collaborating with test and instrumentation teams to close the gap between simulation and physical testing.

• Own the development of automated simulation and optimization workflows to systematically evaluate fluid routing, pressure drops, and cooling loop efficiencies.

• Partner with electrochemical, mechanical, and power electronics teams to resolve complex, multi-factor thermal-fluid anomalies during product integration.

• Suggest and exercise judgment in selecting simulation methodologies, mesh structures, and boundary condition assumptions to proactively identify hot spots and thermal risks.

• Drive the standardization of internal modeling workflows and establish rigorous peer design reviews to ensure technical simulation excellence.

• Model initiative by identifying limitations in our physics-based toolsets and building customized, robust tools to eliminate engineering development blocks.

What you'll bring:

• Experience with a Bachelor's degree and 8+ years of related work experience, or a Master's degree and multiple years of experience, or a PhD with deep focus on thermal-fluid sciences and some industry experience.

• Deep technical expertise in commercial computational fluid dynamics codes and meshing software, such as Ansys Fluent, Star-CCM+, or Comsol Multiphysics.

• Strong foundational knowledge of conjugate heat transfer, fluid dynamics, multiphase flow, and closed-loop cooling systems.

• Applied experience using scripting languages like Python or MATLAB to post-process, visualize, and automate massive multi-physics datasets.

• Demonstrated track record of translating complex simulation results into actionable, physical system-level requirements that guide design decisions.

• Ability to build formal networks outside your immediate area of expertise to achieve technical alignment on mul