Senior Director, Process & Manufacturing Engineering, Electrodes

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 pioneering a new class of battery technology to transform the grid. We are seeking a visionary manufacturing engineering leader to develop, industrialize and scale up our innovative electrodes manufacturing. 

You’ll spearhead the translation of novel R&D into robust, validated, high-throughput processes—driving equipment design, process innovation, and production readiness. This is a critical leadership role at the intersection of product, process, and equipment engineering, requiring first-principles thinking and operational rigor.

What you'll do:

• Build and lead a world-class team of multidisciplinary engineers focused on electrodes process and equipment development and scale up.  

• Set the vision and operating system for the advanced manufacturing organization —driving a culture of excellence, urgency, data-driven iteration, and technical rigor.

• Own and drive the end-to-end process & equipment development roadmap, design, sourcing and deployment for both our Anode and Cathode

• Translate product requirements into scalable, cost-effective processes with integrated quality and inspection methods.

• Downselect novel manufacturing approaches via pilot trials, optimizing tradeoffs in cost, yield, and performance.

• Lead PFMEAs, DOE-based experimentation, and root cause analyses to drive high process capability and robust control plans.

• Design and commission high-volume production equipment, from pilot tools to fully automated factory lines.

• Guide equipment supplier selection and strategy, setting Form’s standards for equipment design, automation, ergonomics, and controls.

• Validate process readiness through factory/site acceptance testing, process optimization, GR&R, and capability metrics (e.g., Cpk, SPC).

• Partner cross-functionally across R&D, product design, operations, and external vendors to align milestones, budgets, and risk management.

What you'll bring:

• 10+ years in process development and scaling high-volume manufacturing lines; 5+ years in technical leadership with people management.

• Track record of launching complex electrochemical or analogous products, ideally in batteries, fuel cells, high volume automation or advanced materials.

• Expertise in a sub-set of the following manufacturing processes: Powder handling, mixing/coating, high-temperature furnaces/sintering, extrusion, calendering, drying, lamination and high volume automation.

• Mastery of quality systems and statistical tools (DOE, SPC, GR&R, capability analysis) to drive continuous improvement.

• Strategic thinker and hands-on leader capable of navigating complexity, ambiguity, and fast-paced development cycles.

• Excellent communication and executive presence—able to align technical teams and influence at the leadership level.

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.

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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.

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.