Senior Mechanical Design Engineer, Structures

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

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

The Structures Engineering team at Form is responsible for designing the structure, enclosure, and sealing systems that supports and integrates all parts of our innovative utility‑scale multi‑day energy storage system. We strive to deliver designs that are optimized for performance, quality, reliability, and cost for high‑volume manufacturing at Form Factory.

We’re seeking a Sr Mechanical Design Engineer to join our team and contribute to the scaling of our multi‑day energy storage system. You'll bring components and assemblies from concept to into mass production, with an emphasis on FEA‑driven structural design, weatherproofing, and manufacturability of metal enclosures. You will work cross‑functionally with designers and test engineers, interrogating the potential design space and selecting appropriate test methods to validate designs. As a problem solver, you will apply your design knowledge of sheet metal, weldments, and sealing systems to balance structural optimization with design for manufacturability, weight reduction, and cost‑down.

Relocation assistance is available.

What You’ll Do

• 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 your designs, utilizing Ansys FEA and hand calcs
• Work closely with test team to initiate test campaigns to establish material libraries for FEA
• Collaborate with test engineers and CAE experts to validate designs through test and FEA correlation
• Present designs, analysis, and test results to broader team and leadership in design reviews
• Perform failure root cause analysis on systems and assemblies
• Travel up to 20% to other Form Energy offices or vendor sites

What You’ll Bring

• Bachelor’s Degree in Mechanical Engineering or related field and 4+ years industry experience in mechanical design and structural analysis
• Experience designing complex mechanical structures, using FEA for structural analysis
• Proficiency in computer‑aided design (CAD), specifically SolidWorks modeling and drafting using GD&T (ASME Y14.5)
• Experience in component design for mass manufacturing and assembly (DFMA), especially sheet metal, stampings, and weldments
• Sense of urgency and self‑driven to hit difficult schedule targets

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.

Compensation Range: $128,662 - $168,844