---
title: 'Senior Process Engineer, Mechanical Assembly at Formenergy'
canonical: 'https://feeny.ai/job/senior-process-engineer-mechanical-assembly-formenergy-weirton-z4mjf4h6kste'
type: 'job'
last_seen: '2026-11-06'
---

# Senior Process Engineer, Mechanical Assembly at Formenergy

- **Company:** [Formenergy](https://feeny.ai/companies/formenergy)
- **Location:** Weirton, WV
- **Employment:** full-time
- **Posted:** 2026-11-04
- **Last confirmed live:** 2026-11-06
- **Apply:** https://jobs.ashbyhq.com/formenergy/c2a3b2eb-3397-4dcb-b517-2726d37136f3

## 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

As a Senior Process Engineer, Mechanical Assembly, you will play a key role in advancing the performance, reliability, and efficiency of our production operations. You'll bring a strong mechanical aptitude and data-driven mindset to analyze operational performance, identify opportunities for improvement, and implement robust, high-impact solutions on the floor. Working closely with cross-functional engineering teams, you will drive continuous improvement initiatives and translate operational insights into meaningful change. You will also serve as a key partner to our systems design team, championing human-centered design principles and providing manufacturing feedback that shapes next-generation equipment — strengthening the manufacturing capabilities that keep our multi-day storage systems reliable at scale.

What you'll do:

- Mentor and direct a tactical team of technicians to stabilize line cadence, troubleshoot downtime, and maintain operational continuity
- Own line metrics — track and analyze OEE, yield, and cycle times to identify bottlenecks and implement data-driven improvements
- Evaluate and vet solutions, applying strong mechanical intuition to assess equipment and process issues on the fly and ensure fixes are robust, safe, and effective
- Drive cross-functional resolution, partnering with sister engineering and manufacturing teams to quickly unblock production constraints impacting quality and throughput
- Foster continuous improvement by initiating tactical CI projects on the floor to eliminate waste, improve operator ergonomics, and optimize machine reliability
- Bridge the gap to design by acting as the voice of the shop floor, surfacing human factors and usability challenges to the systems engineering team

What you'll bring:

- Bachelor's degree in Mechanical, Manufacturing, Industrial Engineering, or a related technical discipline
- 3-7 years of hands-on experience in a manufacturing, production, or fast-paced industrial operations environment
- Demonstrated ability to manage, prioritize tasks for, and develop a technical team
- Strong familiarity with manufacturing metrics (OEE, downtime tracking) and a practical, root-cause approach to problem-solving
- Solid understanding of mechanical systems and automated equipment, with the confidence to vet technical solutions and guide floor-level fixes
- Exceptional interpersonal skills, with the ability to influence cross-functional peers and present clear improvement ideas to design engineers
- A proactive, get-it-done attitude, intellectual curiosity, and comfort thriving amid ambiguity as we scale our technology

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.

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)

## Other roles at Formenergy

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- [EHS Engineer](https://feeny.ai/job/ehs-engineer-formenergy-weirton-4fva01hwkxsg) — Weirton, WV
- [Director, Supplier Industrialization Engineering](https://feeny.ai/job/director-supplier-industrialization-engineering-formenergy-berkeley-hwavx46rcd1s) — Berkeley, CA
- [Mechanical Engineer II, R&D](https://feeny.ai/job/mechanical-engineer-ii-r-d-formenergy-somerville-yyf7y2y1qpx1) — Somerville, MA
- [Contract Recruiter](https://feeny.ai/job/contract-recruiter-formenergy-united-states-e3z3c36jjqjs) — United States
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