Senior Process Engineer, Cathode

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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 Senior Process Engineer 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 Senior Process Engineer, you will have a direct impact on the design and operations of the equipment that creates our Cathode. You will run trials, analyze data, and identify key process inputs to analytically develop new processes and scale our production. You will also contribute heavily to the automation of quality and verification standards. Your background 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 atForm 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

  • Establish metrics and use quality data to define good process windows

  • Demonstrate ownership and accountability in running process trials and making 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 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:

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

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

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

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

  • Experience with PFMEAs, factory acceptance testing, and process validation

  • Experience authoring process, safety, and quality documentation for best-in-class practices

  • Excellent communication and organizational skills

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

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



Humanity is a cornerstone of Form Energy’s culture, and we make sure our compensation and benefits reflect that. Form Energy offers competitive salaries, stock options, and a holistic benefits package to ensure all employees have what they need to thrive while working here.

When it comes to you and your family’s health, we cover 100% of medical, dental, and vision premiums for full-time employees - and 80% of healthcare premiums for dependents. This starts from day one. We also offer at least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents), and generous vacation policies to give employees time to recharge when needed.

To build a clean and equitable energy future, we need everyone at the table. We strive to form a team as diverse as the communities we will serve with our technology, and are committed to maintaining an inclusive environment for all employees. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.