---
title: 'Senior Mechanical Engineer, Manufacturing R&D at Formenergy'
canonical: 'https://feeny.ai/job/senior-mechanical-engineer-manufacturing-r-d-formenergy-somerville-546qp2rnbs4w'
type: 'job'
last_seen: '2026-10-16'
---

# Senior Mechanical Engineer, Manufacturing R&D at Formenergy

- **Company:** [Formenergy](https://feeny.ai/companies/formenergy)
- **Location:** Somerville, MA
- **Compensation:** $129k–$161k
- **Employment:** full-time
- **Work type:** onsite
- **Posted:** 2026-06-12
- **Last confirmed live:** 2026-10-16
- **Apply:** https://jobs.ashbyhq.com/formenergy/8d88022e-9218-49ba-8152-a1d6eb1b1fa8/application

**Skills:** Mechanical CAD tools, Project planning software, PDM/ERP systems, DFMEA, PFMEA, Process development, Value engineering, Time-study cost savings, Equipment automation, Battery experience, Energy systems experience

> Join Form Energy's Core Technology Hardware team to establish build line equipment, processes, and workflows for battery test vehicle manufacturing. This role involves driving line bringups, leading technical assessments, and mentoring team members to support critical battery data production.

## 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 is hiring a Senior Mechanical Engineer to join our Core Technology Hardware team. In this role, you will lead the design, development, and deployment of custom manufacturing equipment and precision assembly fixtures to support our low-volume battery test vehicle manufacturing lines. As a technical leader within our manufacturing R&D group, you will bridge early-stage technology discovery and physical execution. This is an extraordinarily collaborative role: you will sit at the center of our hardware feedback loop, working side-by-side with test vehicle design engineers, hands-on assembly technicians, battery scientists designing experiments, and the test infrastructure and execution teams who bring our testing operations to life. This is an exciting opportunity to help shape and be part of the growth of a fast-moving company with breakthrough technology and an incredible mission!

Relocation assistance is available.

What you'll do:

- Develop novel designs of mechanical and electromechanical manufacturing equipment, ranging from manual assembly fixtures to semi-automated and fully automated tooling
- Drive new manufacturing line bring-ups as existing products evolve or new test vehicles come online, continuously triaging existing line capabilities against new product revisions and custom R&D experiments
- Identify and mitigate manufacturing risks early through design reviews, DFMEA/PFMEAs, process control plans, and hands-on evaluations of vendor proposals
- Lead technical assessments of R&D build processes on the shop floor, identifying bottlenecks and driving continuous improvements in cycle time, yield, and quality.
- Fabricate custom or one-off test vehicles upon request—delivering everything from quick, scrappy proof-of-concept assemblies to highly polished, specialized testing units.
- Establish standards for equipment design, vendor management, commissioning, and cross-team data collaboration. Bring exceptional attention to detail to technical presentations, engineering drawings, and cross-functional project leadership.
- Lead by example and mentor junior engineers, building a culture of technical rigor in equipment design, documentation, and repeatable manufacturing execution
- Mentor manufacturing R&D team members, leveraging a proven track record of building and documenting repeatable manufacturing processes and equipment to elevate team capabilities.

What you'll bring:

- Bachelor’s degree in Mechanical Engineering, Electromechanical Engineering, or related field with 4+ years of relevant experience (battery or energy systems experience is a plus).
- Hands on design and build experience.
- Proficiency in mechanical CAD tools, software tools for project planning, and PDM/ERP systems.
- Demonstrated experience in medium to high volume manufacturing lines of electromechanical products including new process development, value engineering exercises, and time-study cost savings efforts.
- Excellent problem-solving skills, with the ability and enthusiasm to balance safety, rigor, and speed.
- Strong communication and collaboration skills with a solution-oriented mindset when faced with spur of the moment obstacles.

#LI-Onsite

## #LI-LN1

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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