Role DescriptionForm Energy is transforming the grid with our innovative Iron-Air battery technology. We are seeking a
Senior Controls Engineer to join our Manufacturing Control and Execution Systems team. This is a high-impact leadership role where you will own the full lifecycle of the novel equipment powering our first high-volume manufacturing facility, Form Factory 1.
As a technical authority, you will lead large-scale projects, mentor a growing team of engineers, and bridge the gap between complex automation design and operational excellence.
Relocation assistance is available.
What you'll do:- Project Leadership: Serve as the technical lead on multiple simultaneous projects, coordinating across Robotics, Vision, and SCADA workstreams to ensure systems are delivered on budget and on schedule.
- System Architecture: Design, develop, and deploy industrial control and execution systems from the ground up, ensuring all equipment meets rigorous safety and performance standards.
- Technical Mentorship: Provide professional and technical guidance to junior automation engineers, fostering a culture of engineering excellence and continuous improvement.
- Equipment Lifecycle Management: Own the control and execution systems throughout their entire lifecycle, including initial design, FAT/SAT at vendor sites, deployment, and long-term sustaining.
- Escalation & Support: Act as the final technical authority for production escalations, resolving complex electrical and controls issues to optimize throughput and minimize downtime.
- Cross-Functional Collaboration: Partner with production, maintenance, and external vendors to integrate MES data transactions, troubleshoot OT network infrastructure, and implement hardware improvements.
What you'll bring:- Experience: 5+ years of hands-on experience in control system design, development, and deployment within a high-volume manufacturing environment.
- PLC Mastery: Strong proficiency in Siemens TIA-Portal, Allen Bradley, orRockwell. Ability to train others and set programming standards is required.
- SCADA & Data: Proven experience executing independently in Ignition, Siemens WinCC, and Rockwell FTView. Deep understanding of PLC-to-MES handshaking and data tracking.
- Robotics & Vision: Proficiency with FANUC (Roboguide) and industrial vision systems (Keyence or Cognex) for inspection and barcode scanning.
- Safety & Networking: Advanced knowledge of Functional Safety (ProfiSafe, CIP Safety, and FANUC DCS) and the configuration of managed OT networks (Siemens Scalance).
- Technical Tools: Experience with iba for data acquisition and Octoplant for version control. Ability to read, redline, and troubleshoot complex electrical schematics.
- Education: Bachelor's degree in Electrical, Controls, or Mechatronics Engineering (or equivalent experience).
- Experience: Extensive controls experience in a manufacturing environment with a proven track record of managing large-scale projects and mentoring engineering teams.
- Skills: Exceptional attention to detail in testing, data documentation, and schematic interpretation.
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.
