Sr. Test Engineer, Electrical & Software Systems

Form Energy; Weirton (WV); On-site; USD 90,000 - 140,000; Full time

Benefits offered by this job

Relocation assistance

Competitive compensation package

Medical, dental, vision coverage

Parental leave (12+ weeks)

Generous vacation policy

Job summary

Form Energy is seeking a Senior Test Engineer to join our Systems Test organization in Weirton, WV. You will translate electrical, software, and controls requirements into comprehensive test procedures and drive execution across cell, module, and multi-pack assets, ensuring data integrity and robust validation of BMS and control algorithms.

The role focuses on test plan development, hardware-software integration, and rigorous fault triage in a high-energy lab environment.

Qualifications

• Bachelor’s degree required in a technical field.
• 5+ years hands‑on experience in electrical test engineering or systems integration.
• Experience deriving test plans, test cases, and verification metrics from requirements/DFMEAs.

Responsibilities

• Lead translation of requirements and DFMEAs into rigorous test plans.
• Drive test plan execution for electrical and software elements across assets.
• Validate BMS hardware, firmware, and control algorithms.
• Execute tests for industrial networks (CAN, Modbus, Ethernet, EtherCAT).
• Triaging test anomalies; analyze schematics, firmware logs, and control scripts.
• Review telemetry and logs; synthesize findings into test reports.
• Manage LOTO requirements and electrical safety in lab environments.

Skills

Electrical test

Software/firmware testing

Systems integration

Test plan derivation

Python/MATLAB/LabVIEW

Education

Bachelor’s degree in Electrical/Software/Systems Eng

Tools

JIRA

Confluence

Jama

Job description

Sr. Test Engineer, Electrical & Software Systems

Location

Weirton, WV

Employment Type

Full time

Location Type

On-site

Department

Engineering Reliability & Test

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 Senior Test Engineer to join our Systems Test organization. In this role, you will be a key contributor focused on driving robust test plans and execution strategies derived directly from electrical, software, and controls requirements, as well as Design Failure Mode and Effect Analyses (DFMEAs). You will oversee the electrical and software test elements across cell, module, and major multi-pack integrated test assets.

These systems serve as the cornerstone of our validation strategy, verifying our custom battery management systems (BMS), power electronics, industrial communication networks, plant control algorithms, and overall system integration.

You will be directly responsible for translating electrical, software, and controls requirements into comprehensive test procedures (VERTs/VALs), executing tests on physical hardware, triaging software/hardware faults, and validating data integrity across test campaigns. The ideal candidate pairs high technical capability in electrical test engineering and software/controls verification with a rigorous first-principles troubleshooting mindset. Relocation assistance is available.

What you'll do:

Lead the review and translation of electrical, software, and controls requirements and DFMEAs into actionable, rigorous test plans and verification test requirements following the Test @ Form process.

Drive test plan execution and validation for electrical and software elements across cell, module stands and integrated multi-pack assets.

Validate BMS hardware, firmware releases, plant software, control algorithms, and safety interlock state machines.

Execute tests focused on industrial communication protocols (CAN, Modbus, Ethernet, EtherCAT), verifying signal mapping, bus traffic, latency, and telemetry robustness.

Act as the primary hands‑on triager when test anomalies occur, analyzing board schematics, harness connections, firmware logs, and control scripts to isolate root causes.

Process and review raw telemetry, software logs, and high‑speed electrical data streams to validate data integrity and synthesize findings into clear test reports.

Manage lock‑out/tag‑out (LOTO) requirements for electrical safety, verify electrical interlocks, and maintain 5S standards within high‑energy laboratory environments.

What you'll bring:

Bachelor’s degree in Electrical Engineering, Computer Engineering, Systems Engineering, Software Engineering, Mechatronics, or a related technical discipline.

5+ years of hands‑on experience in electrical test engineering, software/firmware test validation, or systems integration (highly valued within battery systems, EV, aerospace, grid‑scale storage, or heavy industrial sectors).

Proven experience deriving test plans, test cases, and verification metrics directly from system requirements, control ConOps, and DFMEAs.

Strong practical familiarity with low‑voltage/high‑voltage electrical schematics, harness design, board‑level testing, and power electronics.

Proficiency writing, editing, or executing automated test scripts using Python, MATLAB, or LabVIEW.

Strong understanding of standard industrial network protocols (CAN, Modbus, Ethernet, EtherCAT) and network telemetry troubleshooting.

Familiarity with Atlassian toolsets (JIRA, Confluence) and requirements management systems (e.g., Jama).

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.

#LI-Onsite

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.

We are proud to be an equal opportunity employer.

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.