Senior Mechanical Design Engineer - Enclosures & FEA

Form Energy; Berkeley (CA); On-site; USD 129,000 - 169,000; Full time

Benefits offered by this job

Relocation assistance

Job summary

Form Energy is seeking a Sr Mechanical Design Engineer to design the structure, enclosure, and sealing systems for its multi‑day energy storage solution. The role emphasizes FEA‑driven structural design, weatherproofing, and manufacturability for high‑volume production.

You will lead from concept to mass production, collaborating with designers, test engineers, and CAE experts to validate through test campaigns and correlation with FEA results. Relocation assistance is available.

Qualifications

• Bachelor’s degree in Mechanical Engineering with 4+ years of industry experience.
• Experience designing complex mechanical structures with FEA.
• Proficient in CAD (SolidWorks) with GD&T (ASME Y14.5).
• Mass manufacturing and DFMA experience with sheet metal, stampings and weldments.
• Self-driven and able to meet tight schedules.

Responsibilities

• Create white-page designs that will be the foundation of Form Energy’s next generation battery pack for high volume production.
• Perform structural analysis of designs using FEA and hand calcs.
• Collaborate with test team to initiate test campaigns and build material libraries for FEA.
• Work with CAE experts to validate designs through test and FEA correlation.
• Present designs, analyses, and test results to the team and leadership in reviews.
• Conduct failure root cause analysis on systems and assemblies.
• Travel up to 20% to other Form Energy offices or vendor sites.

Skills

FEA analysis

Sheet metal design

DFMA

4+ years experience

Education

Bachelor’s Degree in Mechanical Engineering

Tools

SolidWorks

Job description

Form Energy is seeking a Sr Mechanical Design Engineer to design the structure, enclosure, and sealing systems for its multi‑day energy storage solution. The role emphasizes FEA‑driven structural design, weatherproofing, and manufacturability for high‑volume production.

You will lead from concept to mass production, collaborating with designers, test engineers, and CAE experts to validate through test campaigns and correlation with FEA results. Relocation assistance is available.