Senior Quality Engineer, Cell Assembly

Form Energy; Weirton (WV); On-site; USD 95,000 - 150,000; Full time

Benefits offered by this job

Relocation assistance

Stock options

Great benefits

Job summary

Form Energy in Weirton, WV is hiring a Senior Quality Engineer to lead quality processes on a high‑automation, high‑volume cell assembly line. You will own PFMEAs, CPs, and inspection methods, and collaborate with Design, Manufacturing, suppliers and operations.

Relocation assistance is available. You will join a team focused on scaling American battery production, delivering reliable energy storage solutions and supporting rapid growth.

Qualifications

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Materials Science or related field.
• Solid experience with SPC, PFMEAs, and Control Plans.
• Strong aptitude with electronic test and measurement systems.
• Proficiency in reading and interpreting mechanical drawings and wiring diagrams.

Responsibilities

• Own and drive quality processes and documentation for cell assembly, including Control Plans, PFMEAs, and inspection/test methods.
• Lead change management and support execution of process development experiments in the cell assembly area.
• Regularly review and revise PFMEAs and Control Plans to reflect process changes and lessons learned.
• Lead identification and resolution of manufacturing quality issues, including root cause analysis and corrective actions.
• Drive continuous improvement activities in partnership with Design/Manufacturing Engineering and external Suppliers.
• Lead Statistical Process Control (SPC) activities and apply critical thinking to systematically reduce variation on high‑automation, high‑volume production lines.
• Lead non‑conforming material control activities for cell assemblies and sub‑components.
• Define, validate, and maintain quality controls and measurement/test methods for resistance welding and laser welding operations.
• Partner with automation and equipment engineering teams to embed quality controls into high‑volume production systems.

Skills

Quality engineering

SPC

PFMEA

Control Plans

DOE

8D problem solving

Data analysis tools

JMP

R

Minitab

High-volume manufacturing

Welding processes

Reading drawings

Education

Bachelor's degree in Mechanical Engineering

Electrical Engineering

Materials Science

Advanced degree

Tools

JMP

R

Minitab

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

We are hiring a Senior Quality Engineer to serve as the quality engineering owner for our Cell Assembly manufacturing area. You will develop and own quality processes and methodologies, lead cross‑functional teams, and partner with Design Engineering, Manufacturing Engineering, Suppliers, and Operations to address quality, reliability, and manufacturability challenges on a high‑automation, high‑volume production line. This is a hands‑on individual contributor role spanning the full product development lifecycle — from R&D validation through pilot and high‑volume production. You will be a critical member of Form Energy's Quality Team, ensuring cell assemblies consistently meet customer and internal requirements. Relocation assistance is available.

What you'll do:

• Own and drive quality processes and documentation for cell assembly, including Control Plans, PFMEAs, and inspection/test methods
• Lead change management and support execution of process development experiments in the cell assembly area
• Regularly review and revise PFMEAs and Control Plans to reflect process changes and lessons learned
• Lead identification and resolution of manufacturing quality issues, including root cause analysis and corrective actions
• Drive continuous improvement activities in partnership with Design/Manufacturing Engineering and external Suppliers
• Lead Statistical Process Control (SPC) activities and apply critical thinking to systematically reduce variation on high‑automation, high‑volume production lines
• Lead non‑conforming material control activities for cell assemblies and sub‑components
• Define, validate, and maintain quality controls and measurement/test methods for resistance welding and laser welding operations
• Partner with automation and equipment engineering teams to embed quality controls into high‑volume production systems

What you'll bring:

• 3–10 years of quality engineering experience in a manufacturing environment (P3: 3–5 years; P4: 5–10 years)
• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Materials Science, or a related field; advanced degree a plus
• Solid experience with SPC, PFMEAs, and Control Plans
• Strong aptitude with electronic test and measurement systems
• Proficiency in reading and interpreting mechanical drawings and wiring diagrams
• Structured problem-solving (8D) and strong statistical skills including DOE, Process Capability (Cpk, Ppk), etc.
• Proficiency with data analysis tools such as JMP, R, Minitab, or equivalent
• Ability to manage, synthesize, and interpret large manufacturing data sets
• Experience with quality engineering in high‑automation, high‑volume manufacturing environments
• Knowledge of resistance welding or laser welding processes, including process control and quality inspection methods, is strongly preferred

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.