Senior Process Engineer, Powder Mixing

Form Energy; Pittsburgh (Allegheny County); On-site; USD 90,000 - 150,000; Full time

Benefits offered by this job

Relocation assistance

Stock options

Comprehensive benefits

Job summary

Form Energy is seeking a Senior Process Engineer – Powder Mixing to join our engineering team in developing, scaling, and optimizing powder mixing for electrode manufacturing on a high-volume production line. You will lead trials, define process requirements, and collaborate with equipment engineers to ensure robust scale-up.

The role emphasizes data-driven decision making, safety, and cross-functional teamwork across manufacturing and design groups as we scale iron-air battery production at

Qualifications

• Bachelor’s degree or higher in a relevant engineering field is required.
• Experience scaling powder processes from lab to production.
• Hands-on experience with industrial mixers and powder characterization is preferred.
• Strong data-driven decision-making and problem-solving skills.

Responsibilities

• Develop, scale, and optimize powder mixing processes for high-volume electrode manufacture.
• Define process requirements and partner with equipment engineers to design, specify, and qualify mixing systems.
• Lead experimental trials on current manufacturing lines to establish process windows, improve quality, and increase throughput.
• Scale-up novel test methods for powder characterization and own the data analysis to evaluate product quality.
• Be a champion for safety while scaling initial process designs to full production volume.

Skills

Powder mixing

Scale-up

Experimental design

Data analysis

Safety

Cross-functional teamwork

Education

Bachelor’s degree in Chemical Engineering, Mechanical Engineering, or Materials Science

Tools

Industrial mixers

Powder handling equipment

Particle characterization

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 bette

r.
Feeling energized to make a meaningful impact on the world? Then keep reading - you’ve come to the right pla

ce.
Role Descrip

tion
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 bat
tery.
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. This is a unique opportunity to take ownership of a critical process area while shaping the future of a transformative energy storage techn
ology.
This role will be located at Form Factory 1 in Weirton, WV, which is just a short drive outside of Pittsburgh, PA. Relocation assistance is avai

lable.
What Y

• ou'll Do
  Develop, scale, and optimize powder mixing processes for high-volume electrode manuf
• acturing.Define process requirements and partner with equipment engineers to design, specify, and qualify mixing
• systems.Lead experimental trials on current manufacturing lines to establish process windows, improve quality, and increase th
• roughput.Scale-up novel test methods for powder characterization and own the data analysis to evaluate product
• quality.Be a champion for safety while scaling initial process designs to full productio

n volume.
What Yo

• u'll Bring
  5+ years of experience with powder mixing, blending, or related powder handling processes in a manufacturing or pilot e
• nvironment.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), powder handling equipment, and/or material characterization (particle size, shape, surface area, fl
• owability).Strong foundation in statistical process control methods, and data-driven decis
• ion-making.Excellent communication and organizational skills, with experience writing process, safety, and quality doc
• umentation.Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a rel

ated field.
Where

You’ll Work
This role is based at Form Factory 1 in Weirton, WV—an easy commute from the city of Pittsburgh, PA. This 550,000-square-foot facility is our hub for high-volume battery production and a leader in the new era of American energy manufacturing. Relocation assistance

is available.
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 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.

with discretion.
Form Energy is committed to maintaining the privacy of our applicants. Please be a

ware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.