---
title: 'Senior Mechanical Engineer, High-Voltage Design at Formenergy'
canonical: 'https://feeny.ai/job/senior-mechanical-engineer-high-voltage-design-formenergy-berkeley-h9k4sqqyxebr'
type: 'job'
last_seen: '2026-09-04'
---

# Senior Mechanical Engineer, High-Voltage Design at Formenergy

- **Company:** [Formenergy](https://feeny.ai/companies/formenergy)
- **Location:** Berkeley, CA
- **Compensation:** $129k–$169k
- **Employment:** full-time
- **Posted:** 2026-09-03
- **Last confirmed live:** 2026-09-04
- **Apply:** https://jobs.ashbyhq.com/formenergy/7f691074-b05c-4b61-857d-17da14bd069d/application

**Skills:** SolidWorks, NX, CAD, Cost modeling, Multi-physics simulations, Thermal analysis, CFD, Structural analysis, GD&T, Hand calculations, High-volume manufacturing, Fabrication, Prototyping, DFM, DFA, Power distribution, Electrical circuits, Protection devices, Creepage and clearance analysis, IEC standards

> Form Energy seeks a Senior Mechanical Engineer to lead the electromechanical design, simulation, and testing of high-voltage battery power systems. The role involves driving designs from concept to mass production while ensuring quality, reliability, and safety in a fast-paced manufacturing environment.

## 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’s HV & LV Design Team is seeking a Senior level Mechanical Design Engineer to drive the HV requirements, design, simulation and testing of our Gen 2 and beyond power systems for clean energy delivery from batteries to the grid. You will be responsible for designing electro-mechanical sub-assemblies that will deliver power and control signals to various auxiliary systems within the battery enclosure. You will take designs from concept to production in a fast paced environment while ensuring quality and reliability through rigorous tests. This role requires collaboration with various engineering teams, making it an exciting opportunity to contribute to cutting-edge technology at a dynamic company with a remarkable mission.

## WHAT YOU'LL DO:

- Provide technical leadership and mentorship within a multidisciplinary engineering team, fostering the growth and problem-solving skills across team members
- Own the electromechanical design of Form’s battery products, including high voltage distribution (busbars and cables), isolation, grounding, harnessing, connectors, overmolded bussing, plastic and metal enclosures for various PCBA and electrical assemblies, and safety and interlocks (contactor, fuses etc.)
- Address challenges related to electronics packaging, encompassing tasks such as electrical isolation, sealing, thermal regulation, interconnection & shock and vibration mitigation
- Leading RCAs and cross-functional interface design
- Mechanical design analysis including thermal, structural, design for assembly, and design for test
- Own the design from conception through all of its iterations to mass-production
- Create drawing packages and manufacturing instructions for parts and assemblies
- Design and develop electromechanical and electrical systems in support of test stand safety, improvements, and simplification

## WHAT YOU'LL BRING:

- A degree in Mechanical/Mechatronics Engineering or a related field; bachelor's with 4+ years, or master's with 3+ years of relevant experience developing medium to high volume products
- Proven experience with electrical and mechanical design and proficiency in CAD (SolidWorks, NX, etc.)
- Expertise in cost modeling, multi-physics simulations (e.g., thermal, CFD, structural), and optimizations, with the ability to navigate system-level trade-offs and integrate them into architecture studies
- Strong mechanical and electrical engineering fundamentals, GD&T, and first principles hand calculations.
- Direct experience with high-volume manufacturing, fabrication, and prototyping techniques; experience with tight-tolerance, component design for harsh environments, DFM/DFA.
- Solid understanding of power distribution, electrical circuits, protection devices
- Superb understanding of creepage and clearance analysis and standards (ie IEC, UL etc.)
- Ability to model resistive losses, run current density analysis to optimize busbar geometry and sizing to meet system performance and mass requirements

## Preferred Qualifications

- Familiar with electrical standards (NEC); experience with battery and power conversion standards (UL9540, UL1741) a plus
- Leadership, the ability to mentor, and well-developed communication, collaboration, and engagement skills working with a variety of teams and stakeholders

#LI-Onsite

## #LI-TR1

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 accommodations@formenergy.com. 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.

## About Formenergy

## Core Business
- **Primary industry**: Energy storage / Clean energy technology / Battery manufacturing
- **Target customers**: Electric utilities, grid operators, large-scale energy developers, and industrial energy users (B2B, enterprise)
- **Mission/purpose**: To reshape the global electric system by creating a new class of low-cost, multi-day energy storage systems that strengthen the grid and enable a sustainable energy future.

## Products & Services
- **Iron-Air Battery System**: A proprietary battery that stores energy for up to 100 hours at a fraction of the cost of lithium-ion. Designed for grid-scale applications to firm renewable energy and replace peaker plants. [formenergy.com](https://formenergy.com/)
- **Formware™**: An advanced software tool that helps utilities and grid operators model the value of multi-day energy storage in their portfolios. [formenergy.com/about](https://formenergy.com/about/)

## Market Standing
- **Valuation**: Not publicly disclosed
- **Key Metric**: Total funding raised > $1.2 billion (as of Series F in 2024)
- **Notable Investors/Partners**: T. Rowe Price (led Series F), Breakthrough Energy Ventures, Prelude Ventures, The Engine, TPG Rise, Coatue Management, ArcelorMittal’s XCarb fund, Eni Next, Capricorn Investment Group. [formenergy.com/about](https://formenergy.com/about/)
- **Growth Signals**:
  - Commercial pipeline exceeds 750 MW / 75 GWh under agreement.
  - Announced 300 MW / 30 GWh project with Xcel Energy to power a Google data center in Minnesota.
  - Selected by U.S. DOE for an 85 MW / 8,500 MWh project in Maine – the largest energy storage project by energy capacity announced globally at the time.
  - First international deployment: 10 MW / 1,000 MWh system with FutureEnergy Ireland.
  - Strategic supply agreement with Crusoe (AI data center company) for 12 GWh of iron-air batteries.
  - Manufacturing facility (Form Factory 1) in Weirton, WV – 550,000 sq ft, employing ~400 people, now in trial production. [formenergy.com/about](https://formenergy.com/about/)

## Competitive Advantages
- **Technology moat**: Iron-air chemistry is fundamentally low-cost (using abundant materials) and safe (no thermal runaway, passed UL9540A).
- **Duration leadership**: 100-hour storage fills a critical gap between short-duration lithium-ion and seasonal storage, enabling true 24/7 renewable power.
- **Manufacturing scale**: First high-volume factory built on a former steel mill site in the U.S., leveraging domestic supply chains and skilled labor.
- **Proven field performance**: Over 34,700 sub-scale cells, 6,200 full-scale cells, 170 modules, and 10+ grid-connected systems tested. [formenergy.com/about](https://formenergy.com/about/)

## Strategic Focus
- Rapidly scaling manufacturing at Form Factory 1 and expanding commercial deployments with major utilities.
- Entering new international markets (Ireland, and exploring others).
- Supporting the energy needs of AI data centers and other high-demand loads through long-duration storage.
- Continuing R&D to improve cell performance and reduce costs further. [formenergy.com/about](https://formenergy.com/about/)

## Why Work Here
- **Culture**: Driven by core values of Humanity, Excellence, and Creativity. Emphasis on inclusion, empathy, pragmatic optimism, and tackling hard challenges.
- **Locations**: R&D in Somerville, MA; engineering in Berkeley, CA; manufacturing in Weirton, WV; remote/hybrid options available for some roles.
- **Benefits**:
  - 100% of medical, dental, and vision premiums covered for employees; 80% for dependents.
  - Health insurance starts day one.
  - Up to 12 weeks paid parental leave (more for birth parents).
  - Stock options granted to all employees.
  - Company-sponsored 401k.
  - Annual professional development budget.
  - Employee Resource Program (financial/legal guidance).
  - Mental health counseling services.
  - Life insurance, short- and long-term disability.
- **Team size**: Nearly 1,000 employees as of early 2025, with plans to grow. [formenergy.com/careers](https://formenergy.com/careers/)
- **Awards**: Recognized as a Breakthrough Energy company; multiple industry accolades for innovation.

## Sources
1. [formenergy.com](https://formenergy.com/)
2. [formenergy.com/about](https://formenergy.com/about/)
3. [formenergy.com/careers](https://formenergy.com/careers/)
4. [linkedin.com](https://www.linkedin.com/company/form-energy)
5. [crunchbase.com](https://www.crunchbase.com/organization/form-energy)

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