Senior Process Engineer, Mixing

Form Energy; Weirton (WV); On-site; USD 80,000 - 100,000; Full time

Benefits offered by this job

Competitive salary

Stock options

100% medical, dental, and vision premiums for employees

12 weeks paid leave for new parents

Generous vacation policies

Job summary

A leading energy technology firm is seeking a Senior Process Engineer to optimize powder mixing processes critical for the performance of advanced electrode manufacturing. The ideal candidate will have over 5 years of experience and a strong background in chemical or mechanical engineering. This role offers competitive compensation and benefits, including full healthcare coverage for employees and generous parental leave policies.

Qualifications

• 5+ years of experience with powder mixing, blending, or related processes.
• Ability to scale powder processes from lab to production.
• Experience writing process, safety, and quality documentation.

Responsibilities

• Develop and optimize powder mixing processes for electrode manufacturing.
• Lead experimental trials and data analysis.
• Ensure safety in scaling processes to full production.

Skills

Powder mixing

Process optimization

Data analysis

Problem-solving

Communication skills

Education

Bachelor’s degree in Chemical Engineering

Materials Science or related field

Tools

High-shear mixers

Plow mixers

Ribbon mixers

Job description

Senior Process Engineer, Mixing

Company: Form Energy

Location: Form Factory 1, Weirton, WV (short drive outside Pittsburgh, PA). Relocation assistance available.

Role Description

Form Energy is hiring a Senior Process Engineer – Powder Mixing to join our world‑class engineering team. Our team is responsible for designing, developing, and scaling cutting‑edge electrode manufacturing processes for Form Energy’s Iron‑Air multi‑day battery. As a Senior Process Engineer, you will lead the development and optimization of powder mixing operations that are fundamental to the performance and reliability of our electrodes. Your expertise in powder handling, mixing, and scale‑up will directly influence the quality, consistency, and throughput of our cathode manufacturing line. You will design and execute experiments, analyze process data, and collaborate with equipment and operations teams to ensure robust and safe scale‑up of our mixing systems.

What you’ll do

• Develop, scale, and optimize powder mixing processes for high‑volume electrode manufacturing.
• Define process requirements and partner with equipment engineers to design, specify, and qualify mixing systems.
• Characterize raw material properties (particle size, shape, surface area, flowability) and correlate them with mixing performance and electrode quality.
• Lead experimental trials and data analysis to establish process windows, improve quality, and increase throughput.
• Develop novel test methods to evaluate product quality and inform process window optimization strategies.
• Champion safety while scaling initial process designs to full production volume.

What you’ll bring

• 5+ years of experience with powder mixing, blending, or related powder handling processes in a manufacturing or pilot environment.
• Demonstrated ability to scale powder processes from lab to production, with a track record of solving complex technical challenges.
• Hands‑on experience with industrial mixers (e.g., high‑shear, plow, or ribbon mixers) and powder handling equipment.
• Strong foundation in process characterization, statistical methods, and data‑driven decision‑making.
• Excellent communication and organizational skills, with experience writing process, safety, and quality documentation.
• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a related field.

Benefits & Compensation

Competitive salary, stock options, and a holistic benefits package. 100% of medical, dental, and vision premiums covered for full‑time employees; 80% for dependents. At least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents). Generous vacation policies.

Equal Opportunity Employer

Form Energy is proud to be an equal opportunity employer and encourages candidates from all backgrounds to apply. If you may require reasonable accommodations to participate in our interview process, please contact [e-mail]. Requests for accommodations will be treated with discretion. For privacy, please note that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.