Senior Mechanical FEA Engineer for Battery Storage Systems

Form Energy; Berkeley (CA); On-site; USD 150,000 - 210,000; Full time

Job summary

Form Energy, an American energy storage company, is hiring a Senior Mechanical Engineer, FEA Analyst, to join the Mechanical Simulation & Analysis team. The role focuses on advanced structural and thermal FEA to ensure designs are robust for large‑scale manufacturing, with pilot lines in Berkeley, CA, and production in Weirton, WV.

This CA position anchors on-site work at our Berkeley office. Candidates should have 8+ years in mechanical simulation, with expertise in ANSYS, Abaqus, and Nastran,

Qualifications

• Bachelor’s Degree in Mechanical Engineering or related field.
• 8+ years of industry experience focused on mechanical simulation and analysis.
• Expert-level knowledge in structural FEA and thermal FEA using standard tools.
• Hands-on experience with FEA model validation and correlation to physical tests.
• Experience with high-volume manufacturing hardware products is a plus.
• Strong communication to translate simulation data for cross-functional teams.

Responsibilities

• Lead structural and thermal FEA and optimization of battery components, modules, and enclosures.
• Develop, refine, and maintain complex FEA models (static, dynamic, nonlinear, thermal-structural).
• Perform model validation and collaborate with test engineers to design physical tests and interpret data.
• Partner with interdisciplinary teams to optimize designs for performance, cost, and reliability.
• Contribute to design reviews and translate FEA results into actionable recommendations.

Skills

FEA analysis

Thermal analysis

Model validation

Cross-functional collaboration

Engineering requirements & FMEA

Topology optimization

Education

Bachelor's Degree in Mechanical Engineering or related field

Tools

ANSYS

Abaqus

Nastran

Job description

Form Energy, an American energy storage company, is hiring a Senior Mechanical Engineer, FEA Analyst, to join the Mechanical Simulation & Analysis team. The role focuses on advanced structural and thermal FEA to ensure designs are robust for large‑scale manufacturing, with pilot lines in Berkeley, CA, and production in Weirton, WV.

This CA position anchors on-site work at our Berkeley office. Candidates should have 8+ years in mechanical simulation, with expertise in ANSYS, Abaqus, and Nastran,