Senior Mechanical Engineer, R&D

Form Energy; Somerville (MA); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

Relocation assistance

Stock options

Holistic benefits package

Job summary

Form Energy is seeking a mechanical engineer to drive design, prototyping, and validation of electrochemical cell architectures as part of the R&D team. You will own experimental hardware from concept through validation, partnering with battery engineers, materials scientists, and other mechanical engineers to de-risk early concepts.

Relocation assistance is available, and you will contribute to a fast-moving company with breakthrough technology and a mission to transform the energy landscape.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field, plus 4+ years experience; or Master’s with 1+ year; or PhD.
• Experience across the full mechanical design cycle from concept to prototyping and validation.
• Proficiency in CAD, drawings, and GD&T; hands-on prototyping and engineering analysis (FEA/CFD).

Responsibilities

• Design, build, and validate prototype mechanical architectures and experimental setups.
• Own the end-to-end design cycle, ensuring requirements are met and refined from results.
• Perform engineering analyses (FEA/CFD, tolerance analysis, materials testing) to support designs.
• Coordinate prototyping with in-house and external manufacturers; manage vendor relations.
• Maintain design records with CAD files, drawings, and test data.
• Identify gaps early and propose solutions; communicate across teams.
• Mentor junior engineers and technicians on prototyping efforts.

Skills

CAD proficiency

Mechanical design cycle

Prototyping techniques

Engineering analysis (FEA/CFD)

Communication skills

Education

Bachelor’s in Mechanical Engineering

Master’s in Mechanical Engineering

PhD in Mechanical Engineering or related

Tools

3D CAD software

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 mechanical engineer to drive mechanical design, prototyping, and validation of electrochemical cell architectures for our next‑generation technology. As part of the R&D team, you will own experimental hardware from concept through validation, partnering closely with other mechanical engineers, battery engineers, and materials scientists to de‑risk early‑stage product concepts. This is an exciting opportunity to be creative while helping to shape the growth of a fast‑moving company with breakthrough technology and an incredible mission! Relocation assistance is available.

What you’ll do:

• Design, build, and validate prototype electrochemical cell architectures and experimental setups, translating functional requirements into hardware that works
• Own the iterative design cycle end‑to‑end, confirming that mechanical and electrochemical requirements are met and refine designs based on experimental results, in close partnership with battery scientists and electrochemists
• Select and carry out the engineering analysis needed to support your designs (e.g., hand calculations, FEA, CFD, tolerance stack‑ups, and materials testing), using judgment about which methods fit the problem
• Drive prototyping both in‑house and through external manufacturers, managing vendor relationships
• Maintain the design record through written documentation, 3D CAD files, engineering drawings, and test data
• Identify design gaps and opportunities early, propose creative solutions, and communicate proactively across engineering and science teams
• Coordinate and mentor junior engineers and technicians on shared prototyping efforts

What you’ll bring:

• Bachelor’s + 4 years work experience; Master’s + 1 year of work experience; or a PhD with degree in Mechanical Engineering or related fields
• Demonstrated depth across the full mechanical design cycle, from concept through prototyping and validation, with a track record of owning designs independently
• Proficiency in computer‑aided design (CAD), including engineering drawings and geometric dimensioning and tolerancing
• Hands‑on experience with a range of metal and plastic prototyping techniques (e.g., laser cutting, 3D printing, machining, welding), and sound judgment about when to build in‑house versus outsource
• Strong engineering analysis skills (e.g., FEA, CFD, tolerance analysis, or materials testing) and the judgment to select the right method for a given problem
• Excellent communication and organizational skills

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.