Senior Mechanical Engineer, Plastics Design

Form Energy; Berkeley (CA); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

Competitive salaries

Stock options

100% medical, dental, and vision premiums

Job summary

Form Energy in Berkeley, CA, is hiring a Senior Mechanical Engineer to design injection-molded plastic components for our innovative iron-air battery cells. You will lead design efforts, focusing on prototype development and validation testing, working closely with manufacturing engineering teams.

The role demands a strong background in Mechanical Engineering with hands-on expertise in product development and CAD software, aimed at contributing to sustainable energy solutions. Form Energy promotes a culture of inclusion and competitive benefits.

Qualifications

• 4+ years of industry experience in mechanical engineering.
• Experience in designing plastic components for manufacturing.
• Proven track record in mechanical testing and validation.

Responsibilities

• Design molded plastic components for energy storage systems.
• Conduct validation testing to meet critical requirements.
• Produce detailed part and assembly drawings.

Skills

End-to-end product development

CAD proficiency

Data analysis skills

Adaptability in startup environment

Education

Bachelor's degree in Mechanical Engineering or related field

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—may 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 Cell Engineering team within the Technology group at Form is multidisciplinary and focused on delivering qualified battery cell designs that meet operational performance targets, at cost and with high reliability, from controlled processes on high‑volume manufacturing lines for Form Energy’s utility‑scale multi‑day energy storage system.

We’re hiring a Senior Mechanical Engineer to join our Cell Engineering Design team in Berkeley, CA. In this role, you will design plastic components for our iron‑air battery cells. There will be a particular focus on injection‑molded plastics, and you will take the lead on design, test plan development, and validation testing of your components. This role will work closely with our manufacturing engineering team to define and support battery cell assembly process and equipment design. You will bring a willingness to become an expert in designing plastic components for manufacturing with injection molding, blow molding, thermoforming, or similar processes. You will also get hands‑on experience with plastic joining methods, such as laser or hot‑plate welding. This is an exciting opportunity to be part of scaling our multi‑day energy storage system at Form and contributing to a sustainable future!

What you’ll do

• Design molded plastic components for implementation in Form Energy’s iron‑air battery cells
• Apply first‑principles engineering to design high‑performance structural plastic and sheet metal components capable of withstanding static and dynamic mechanical loads
• Own analysis, prototyping, and failure analysis efforts for plastic components
• Fabricate first‑of‑a‑kind plastic prototypes for mechanical fit checks and verification testing
• Conduct validation testing to prove that designs meet critical requirements
• Negotiate interface requirements with Battery Module and Electrode teams
• Produce and release detailed 2D part and assembly drawings; define technical specifications (dimensional, functional, performance, manufacturing)

What you’ll bring

• Degree in Mechanical Engineering, or related field; Bachelor’s with 4+ years of industry experience
• Experience with end‑to‑end product development, from concept to launch
• Proficient in CAD and engineering analysis to drive design decisions
• Strong data analysis skills, especially with respect to mechanical test results
• Ability to thrive in a fast‑paced startup environment

Benefits & Company Commitment

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.