Senior Process Engineer, Leak Testing

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 a Staff Engineer specializing in testing to join our Advanced Manufacturing Engineering team. Together, we’re responsible for designing, developing, optimizing, and scaling up new manufacturing processes for Form Energy’s Iron-Air multi-day battery.

In this role, you will play a crucial role in developing new methods and processes to ensure the stability of novel manufacturing of our core battery assembly technologies. You will focus on developing in process testing, including leak testing, Hipot, and weld quality (ie resistance). Your work will make a significant and daily impact on cutting-edge battery technology that will revolutionize the electric grid and bring major change to grid reliability and sustainability. This is a fantastic opportunity to join a 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:

• Lead the development and optimization of testing processes, such as leak testing and Hipot/continuity testing for novel battery manufacturing technologies.

• Partner closely with our Equipment team to design, build, install, and run equipment for our first-of-kind manufacturing processes.

• Collaborate with the product design team, R&D, quality, and supply chain, to translate product requirements into process and testing requirements.

• Ensure highly capable processes are developed and demonstrated ahead of detailed equipment design. Measure process capability and evaluate limit samples.

• Conduct process capability studies, utilize statistical analysis tools (e.g., Design of Experiments). Lead troubleshooting efforts to identify root causes of manufacturing issues and implement corrective actions to prevent recurrence while optimizing processes.

• Develop and maintain process procedures, specifications, and standards.

• Develop and maintain PFMEA, process specifications, measurement systems GR&R, control plans, and quality inspection methods (incoming, outgoing, and in-process).

• Demonstrate ownership and accountability, making a major impact on our battery technology owning novel testing methods and processes from concept to high volume production in a fast-paced environment.

• Provide data-driven feedback to the Design team (DFM) to simplify product design for improved manufacturability.

• Develop novel test methods to evaluate products in real time during production.

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

• Drive yield, quality, and performance through a data-driven approach.

What you'll bring:

• Bachelor’s degree in Chemical Engineering, Materials Science, Mechanical Engineering, Manufacturing Engineering, or equivalent.

• 7+ years of experience in a fast-paced manufacturing or production environment, ideally in process engineering or manufacturing engineering.

• H