Senior Mechanical Engineer — FEA & Thermal Analysis

Form Energy; Berkeley (CA); On-site; USD 128,662 - 168,844; Full time

Benefits offered by this job

Stock options

Holistic benefits package

Paid parental leave

Generous vacation

Job summary

Form Energy in Berkeley, CA, is hiring a Senior Mechanical Engineer, FEA Analyst, to drive structural and thermal simulations for our iron‑air battery systems. You will work closely with mechanical, electrical, and systems teams to validate models and guide design decisions, with pilot lines in Berkeley and production lines in Weirton.

You will own high‑fidelity FEA models, push for robust validation, and influence design choices to balance performance, cost, and reliability across the full

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 8+ years of industry experience focused on mechanical simulation and analysis.
• Strong hands-on FEA model validation and correlation with test data.

Responsibilities

• Lead structural and thermal FEA for battery components, modules, and enclosures.
• Build, refine, and maintain complex FEA models for design decisions.
• Validate models with physical tests and data to ensure accuracy.
• Collaborate with cross-functional teams to optimize performance and cost.
• Translate simulation results into clear design recommendations.

Skills

FEA analysis

Mechanical simulation

Technical communication

Topology optimization

Education

Bachelor's Degree in Mechanical Engineering

Tools

ANSYS

Abaqus

NASTRAN

Job description

Form Energy in Berkeley, CA, is hiring a Senior Mechanical Engineer, FEA Analyst, to drive structural and thermal simulations for our iron‑air battery systems. You will work closely with mechanical, electrical, and systems teams to validate models and guide design decisions, with pilot lines in Berkeley and production lines in Weirton.

You will own high‑fidelity FEA models, push for robust validation, and influence design choices to balance performance, cost, and reliability across the full