Senior Process Engineer, Welding

Form Energy; Weirton (WV); On-site; USD 95,000 - 125,000; Full time

Benefits offered by this job

Relocation assistance

Stock options

Comprehensive benefits package

Paid parental leave

Job summary

Form Energy, a leader in long-duration energy storage, is hiring a Weld Engineer for its Weirton, WV facility. You will optimize welding processes across high-volume production, drive cost savings and quality improvements, and collaborate with engineering, manufacturing, and IT teams to scale manufacturing for iron-air batteries.

You will lead data-driven improvements, implement robust controls, and mentor teams while supporting safety and sustainability goals in a fast-growing environment.

Qualifications

• 5+ years in a fast-paced manufacturing environment with welding focus
• Bachelor's degree in Mechanical Engineering, Welding Engineering, or equivalent
• Master welding processes ownership and accountability for quality, throughput and yield
• Deep expertise in laser, resistance, and ultrasonic welding; laser weld monitoring a plus
• Advanced statistics for process development (JMP, Minitab) and SQL data querying
• Experience leading multidisciplinary weld-process improvement projects
• DFMEAs/PFMEAs and robust controls for system-wide risk
• Strong problem-solving, communication, and collaboration in a high-growth setting
• Willingness to relocate to Weirton, WV

Responsibilities

• Lead continuous improvements to optimize welding processes, reduce costs, improve quality and efficiency
• Collaborate with cross-functional teams to solve welding-related production issues while maintaining quality
• Perform root cause analyses and implement corrective/preventive actions for welding equipment and processes
• Define KPIs and monitor targets for manufacturing performance and process capability
• Ensure compliance with safety, environmental and health standards and policies
• Utilize PLM, MES, and ERP systems to enhance manufacturing intelligence and sustainability tracking
• Support factory layout optimization, capacity planning and scalability initiatives

Skills

Welding processes

Root cause analysis

Data analysis (SQL)

Project leadership

DFMEA/PFMEA

Continuous improvement

Cross-functional collaboration

Manufacturing process optimization

Education

Bachelor's degree in Mechanical Engineering

Welding Engineering or related field

Tools

JMP

Minitab

SQL

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 Weld Engineer to join our Operations Engineering team and help scale production of our iron-air battery. In this role, you will drive the optimization of critical welding processes, using data-driven insights to enhance quality, throughput, and yield. You will collaborate with others across the organization to bridge the gap between process development and high-volume execution, ensuring our welding processes are both robust and scalable. By managing these technical improvements, you will directly enable the delivery of long-duration energy storage systems essential for a stable electric grid.

Relocation assistance is available.

What you'll do:

• Lead continuous improvements to optimize welding processes, reduce costs, improve quality, and increase efficiency
• Drive collaboration with cross-functional teams to identify and solve welding-related production issues while maintaining rigorous product quality standards
• Conduct root cause analysis and develop comprehensive corrective and preventive actions to improve large-scale welding equipment, processes, and systems
• Establish and analyze key performance indicators to identify strategic areas for improvement and ensure high-level production targets are met or exceeded
• Ensure organizational compliance with all safety regulations and company policies related to environmental, health, and safety
• Drive optimized usage of PLM, MES, and ERP systems to enhance manufacturing intelligence and sustainability tracking
• Support factory layout and optimization efforts, capacity planning, scalability plans, crew cycling, tool cycling, etc

What you'll bring:

• 5+ years of experience in a fast-paced manufacturing or production environment with a focus on welding, and a Bachelor's degree in Mechanical Engineering, Materials Science, Welding Engineering, or equivalent
• Demonstrated mastery in owning welding processes and showing accountability for their quality, throughput, yield, and overall success
• Deep technical expertise in welding processes and parameters (e.g., laser welding, resistance welding, ultrasonic welding); experience with laser weld monitoring (LWM) systems is a plus
• Advanced proficiency using statistical methods for making process development decisions (using JMP or Minitab or equivalent), with a high level of proficiency on SQL data query
• Extensive experience leading multidisciplinary projects and mentoring engineering teams in weld process improvement and industrial best practices
• Deep technical expertise in creating DFMEAs and PFMEAs and implementing robust controls for system-wide risk mitigation
• Pragmatic problem-solving skills and a history of thriving on complexity within a high-growth manufacturing environment
• Intellectual curiosity and a drive for continuous learning to solve the unique challenges of long-duration energy storage
• Strong verbal and written communication skills to effectively collaborate with multidisciplinary teams and present on technical findings
  

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 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.