Staff Process Engineer, Robotics

Form Energy; Weirton (WV); On-site; USD 110,000 - 140,000; Full time

Benefits offered by this job

Relocation assistance

Stock options

Comprehensive benefits

Job summary

Form Energy in Weirton, WV, is hiring a Staff Manufacturing Engineer to lead automated systems and equipment strategies for ramping production of iron-air batteries. You will own processes and improvements of robotic cells, driving decisions to eliminate bottlenecks and ensure long-term reliability.

You will partner with design and process teams to optimize for high-speed, fully automated manufacturing, delivering a world-class production environment and scalable energy storage solutions.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field and 7+ years of experience.
• Experience with semi-manual and automated assembly processes for complex systems.
• Demonstrated expertise with Fanuc Robotics and Siemens PLCs or similar.
• Experience providing DFM/DFA feedback to improve manufacturability.

Responsibilities

• Own and improve semi-manual and automated manufacturing processes for modular products.
• Define and implement OEE and equipment performance metrics to identify loss drivers.
• Collaborate with design and process development to optimize for fully automated, high-speed manufacturing.
• Lead cross-functional alignment to integrate automation solutions and instrumentation.
• Lead root-cause analysis of issues to drive durable automation improvements.
• Support production ramp and sustaining operations, stabilizing builds across shifts.
• Mentor multidisciplinary engineering teams in automated system design and problem-solving.

Skills

Automation engineering

Root cause analysis

Cross-functional collaboration

Technical leadership

Communication

Education

Bachelor’s degree in Mechanical Engineering

Tools

Fanuc Robotics

Siemens PLCs

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.

Job Description

We’re hiring a Staff Manufacturing Engineer within our growing Operations Engineering team. In this role, you will serve as a primary technical lead for the automated systems and equipment strategies required to ramp production of our iron air battery. You will own the processes and improvements of complex robotic cells and automated hardware, driving technical decisions that eliminate manufacturing bottlenecks and ensure long‑term equipment reliability. By continuously improving standards for automation and precision control, you will ensure our production environment delivers a high volume of top quality products. Your leadership will be the cornerstone in transforming advanced battery technology into a world‑class, automated manufacturing reality that secures global energy reliability.

What You’ll Do

• Own and improve semi-manual and automated manufacturing processes for modular products.

• Define and implement OEE and equipment performance metrics to identify loss drivers and prioritize improvement work.

• Collaborate with product design and process development engineering to provide DFM/DFA feedback, ensuring optimization for fully-automated, high-speed manufacturing.

• Drive cross-functional alignment with controls and equipment teams to integrate automation solutions such as torque tools, lift devices, vision checks, interlocks, and other instrumentation.

• Lead root‑cause analysis of assembly and quality issues, turning findings into durable automation improvements that ensure safe and repeatable production.

• Support production ramp and sustaining operations, stabilizing builds and reducing variation across shifts

• Mentor and guide multidisciplinary engineering teams, fostering a culture of technical excellence in automated system design and pragmatic problem‑solving.

What You’ll Bring

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Robotics, Controls, or a related discipline and 7+ years of relevant experience.

• Deep technical understanding of semi-manual and automated assembly processes for complex systems

• Demonstrated expertise with Fanuc Robotics and Siemens PLCs or similar.

• Extensive experience developing assembly methods, tooling, fixtures, and work instructions in an automated production environment.

• Proven track record of providing DFM/DFA feedback to product design and process development teams, influencing part design, interfaces, tolerances, and fastening strategies to improve manufacturability.

• Strong problem‑solving skills with the ability to identify and address process, design, and human‑factor-driven issues.

• Effective communicator across production, quality, and design teams.

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.