Senior Cathode Process Development Engineer

Form Energy; Weirton (WV); On-site; USD 110,000 - 170,000; Full time

Job summary

Form Energy is seeking a Senior Cathode Process Development Engineer to prototype cathode designs and maintain a development line. You will lead first‑of‑a‑kind prototypes, design DOEs, apply SPC, and install new equipment, partnering with the design team and manufacturing engineering.

Relocation assistance is available and the role is based at Weirton, WV. You will mentor technicians, document processes, and drive safety while scaling mature processes to production.

Qualifications

• 5+ years of experience in process development.
• Experience purchasing and setting up benchtop and automated equipment, and writing SOPs.
• Able to perform hands-on build and test of workstations and equipment.

Responsibilities

• Build and qualify first‑of‑a‑kind prototypes on the cathode development line.
• Design and execute DOEs and ladder studies to connect parameters to material properties.
• Apply SPC and root-cause methods to troubleshoot deviations and drive corrective actions.
• Install, commission, and qualify new equipment and processes with defined specs.
• Develop and maintain process control plans, SOPs, and instructions for handoff to production.
• Partner with manufacturing engineering to transfer processes to production scale.
• Provide technical guidance to technicians and associates.
• Champion safety through job hazard analyses for new trials.

Skills

Process development

DOE design

Statistical process control

Equipment installation

Team guidance

Education

Bachelor's in Engineering, materials science, or equivalent STEM

Tools

Benchtop equipment

Automated equipment

SOP documentation

Job description

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

Form Energy is hiring a Senior Cathode Process Development Engineer to prototype new cathode designs and maintain a process development line.

As a Senior Cathode Process Development Engineer, you will lead the build and qualification of first‑of‑a‑kind prototypes on our cathode development line, working closely with our design team. You will drive process improvements by designing and executing DOEs, applying statistical process control to troubleshoot deviations, and installing new equipment. Beyond technical execution, you will develop process documentation such as SOPs and control plans, partner with manufacturing engineering to scale mature processes, provide technical guidance to associates, and champion safety by leading job hazard analyses for new trials.

Relocation assistance is available.

What You’ll Do

• Build and qualify first‑of‑a‑kind prototypes on our cathode development line in close collaboration with our design team in Somerville, MA
• Design and execute process‑related DOEs and ladder studies to connect process parameters to material properties, characterizing materials to inform design and process decisions
• Apply statistical process control and root‑cause methods (5‑why, fishbone, etc.) to troubleshoot equipment/process deviations and drive corrective action
• Install, commission, and qualify new equipment and processes, defining specifications to guide equipment purchasing
• Develop and maintain process control plans, SOPs, and work instructions, documenting process knowledge for handoff to manufacturing engineering
• Partner with manufacturing engineering to transfer mature processes from development to production scale
• Provide technical guidance to a team of technicians and associates
• Champion safety by partnering with our safety team on job hazard analyses before trialing new processes

What You’ll Bring

• 5 years of experience in process development
• Demonstrated experience in purchasing and setting up benchtop and automated equipment, and writing standard operating procedures
• Readiness to perform hands‑on build and test of workstations and equipment
• Excellent spoken and written communication skills and ability to effectively collaborate with a wide range of other professionals and suppliers
• Knowledge of basic battery operating principles
• Knowledge of common battery manufacturing processes
• Bachelors Engineering, material science, or equivalent STEM background

Where You’ll Work

This role is based at Form Factory 1 in Weirton, WV—an easy commute from the city of Pittsburgh, PA. This 550,000‑square‑foot facility is our hub for high‑volume battery production and a leader in the new era of American energy manufacturing.

Relocation assistance is available.

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 America’s energy future, we need everyone at the table. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.

If you may require reasonable accommodations to participate in our interview process, please contact [e-mail]. Requests for accommodations will be treated with discretion.

Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.