Role DescriptionAs the Senior Manager of Battery Manufacturing Engineering, you serve as the primary architect of the production lifecycle, bridging the gap between research prototypes and high-volume factory operations. You will lead a multidisciplinary team of engineers to develop and internalize robust manufacturing processes for both battery enclosures and module/pack assembly-including robotic joining, sealing, electrolyte filling, and leak testing. By owning the full equipment lifecycle, from defining detailed user requirements through to factory testing and final site commissioning, you ensure that production lines are world-class, delivering a "machine that builds the machine" with precision and technical rigor.
Strategically, your objective is to drive operational scale by ensuring products are designed specifically for ease of manufacturing and assembly during the earliest development phases. You will champion a data-driven culture that utilizes failure mode analysis and advanced root-cause investigation to reduce production risks and achieve aggressive targets for quality, output rate, and equipment uptime. By fostering collaboration between Product Design, Quality, and Supply Chain, you will manage the critical transition from initial design to full-scale production, ensuring that every process is statistically validated to guarantee long-term reliability and cost-effectiveness.
This opportunity is based out of Form Factory 1 - Form Energy's 550,000-square-foot, state-of-the-art manufacturing facility located in Weirton, WV, a commutable distance from Pittsburgh. Purpose-built for high-volume, advanced battery production, Form Factory 1 is a hub of fast-moving, collaborative work driving a new era of large-scale American energy manufacturing in the heart of the Rust Belt.
Relocation assistance is available.
What you'll do:- Lead the development and optimization of battery manufacturing processes for battery assembly manufacturing.
- Ensure highly capable processes are identified and demonstrated for our production facilities ahead of detailed equipment design.
- Oversee the design and implementation of manufacturing processes such as: manual and robotic assembly, joining, sealing, system leak testing, and quality checks to achieve optimal performance and reliability.
- Collaborate with product design team, R&D, quality, and supply chain, to translate product requirements into a battery design and manufacturing process that achieve our company targets.
- Collaborate cross functionally to develop and maintain PFMEA, process specifications, measurement systems GR&R, control plan, and quality inspection methods (incoming, outgoing, and in-process).
- Lead troubleshooting efforts to identify root causes of manufacturing issues and implement corrective actions to prevent recurrence.
- Internalize responsibility for delivery of equipment and processes that enable the operations team to achieve factory production metrics (quality, yield, rate, and availability).
- Identify trends/correlations, and make data-driven decisions for process optimization.
What you'll bring:- Hands-on experience in a high-volume manufacturing organization.
- Bachelor's degree in Mechanical engineering, Chemical Engineering, Electrical Engineering.
- 10 years of experience in engineering roles within battery manufacturing or a related industry, with expertise in complex assembly processes. 4+ leading technical teams.
- Demonstrated experience in manufacturing equipment procurement, setup, and commissioning, including a clear understanding of equipment qualification and validation protocols.
- Strong understanding of lean manufacturing principles and their application in a high-volume production environment.
- Proven track record of successfully leading cross-functional teams in the development and optimization of manufacturing processes for electrochemical systems.
- Proficiency in process engineering principles, statistical analysis, and quality management systems for process optimization and improvement.
- Strong communication skills with the ability to collaborate effectively with multidisciplinary teams and convey technical concepts to diverse stakeholders.
- Leadership and mentoring abilities with a commitment to fostering a culture of continuous learning and accelerated innovation through quick iteration.
- Experience working in a fast-paced startup environment is a plus.
#LI-Onsite
#LI-DL1
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.
