Staff Process Engineer, Laser WeldingManufacturing Engineering * Weirton, WV * Full time * On-site

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. Trial production of our iron-air batteries has already begun, and this year, production will take off to high volumes at our new factory 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.

We are hiring a Staff Process Engineer, Laser Welding to lead the development, optimization, and implementation of advanced laser welding processes. This role is critical in enabling robust, scalable joining technologies for applications in cell assembly. The ideal candidate will have deep expertise in laser welding fundamentals, metallurgy, and equipment integration, along with strong cross-functional collaboration skills.

Your work will make a significant and daily impact on cutting-edge battery technology that will revolutionize the electric grid and bring major change to grid reliability and sustainability. This is a fantastic opportunity to join a company with a direct impact on the nature of energy storage and renewables.

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 available.

What You'll Do:

• Develop and optimize laser welding processes for dissimilar and similar materials across a variety of thicknesses and joint types.

• Design and execute Design of Experiments (DOE) to identify optimal process parameters for weld strength, electrical resistance, quality, and repeatability.

• Conduct in-depth studies of material interactions, weld pool dynamics, heat-affected zones (HAZ), and microstructural evolution.

• Collaborate with product design teams to ensure weld joint geometry is optimized for manufacturability and performance.

• Specify, source, and qualify laser welding systems, beam delivery optics, and process monitoring equipment (weld monitoring, pyrometers, cameras etc).

• Perform weld characterization and failure analysis using cross-sections, microscopy, tensile/shear testing, and NDE techniques.

• Develop and implement in-process monitoring and control strategies to ensure real-time weld quality assurance.

• Author process documentation: weld specifications, control plans, PFMEAs, and standard operating procedures.

• Support transfer of laser welding processes to pilot or high-volume manufacturing environments.

• Mentor junior engineers and technicians in best practices for laser welding development and validation.

• Develop and maintain FMEA, Process specifications, measurement systems GR&R, Control plan, statistical process control (SPC), and quality inspection methods.

• Mentor, guide, and support team members with your expertise and practical experience

What You'll Bring:

• Bachelors degree in Mechanical Engineering, Materials Science, Welding Engineering, or a related field.

• 7+ years of hands-on experience in laser welding process development, preferably in a high volume manufacturing environment.

• Strong understanding of metallurgy, welding metallurgy, and microstructure-property relationships.

• Proficiency in weld quality inspection methods: optical microscopy, X-ray, ultrasonic, etc.

• Expertise in statistical understanding and data analysis skills using MATLAB, Python, JMP, or similar tools.

• Experience welding dissimilar metals (e.g., steel to aluminum, titanium to copper)

• Excellent technical writing and communication skills.

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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.

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.