Role DescriptionForm Energy's HV & LV Design Team is seeking a Senior level Mechanical Design Engineer to drive the HV requirements, design, simulation and testing of our Gen 2 and beyond power systems for clean energy delivery from batteries to the grid. You will be responsible for designing electro-mechanical sub-assemblies that will deliver power and control signals to various auxiliary systems within the battery enclosure. You will take designs from concept to production in a fast paced environment while ensuring quality and reliability through rigorous tests. This role requires collaboration with various engineering teams, making it an exciting opportunity to contribute to cutting-edge technology at a dynamic company with a remarkable mission.
What you'll do:- Provide technical leadership and mentorship within a multidisciplinary engineering team, fostering the growth and problem-solving skills across team members
- Own the electromechanical design of Form's battery products, including high voltage distribution (busbars and cables), isolation, grounding, harnessing, connectors, overmolded bussing, plastic and metal enclosures for various PCBA and electrical assemblies, and safety and interlocks (contactor, fuses etc.)
- Address challenges related to electronics packaging, encompassing tasks such as electrical isolation, sealing, thermal regulation, interconnection & shock and vibration mitigation
- Leading RCAs and cross-functional interface design
- Mechanical design analysis including thermal, structural, design for assembly, and design for test
- Own the design from conception through all of its iterations to mass-production
- Create drawing packages and manufacturing instructions for parts and assemblies
- Design and develop electromechanical and electrical systems in support of test stand safety, improvements, and simplification
What you'll bring:- A degree in Mechanical/Mechatronics Engineering or a related field; bachelor's with 4+ years, or master's with 3+ years of relevant experience developing medium to high volume products
- Proven experience with electrical and mechanical design and proficiency in CAD (SolidWorks, NX, etc.)
- Expertise in cost modeling, multi-physics simulations (e.g., thermal, CFD, structural), and optimizations, with the ability to navigate system-level trade-offs and integrate them into architecture studies
- Strong mechanical and electrical engineering fundamentals, GD&T, and first principles hand calculations.
- Direct experience with high-volume manufacturing, fabrication, and prototyping techniques; experience with tight-tolerance, component design for harsh environments, DFM/DFA.
- Solid understanding of power distribution, electrical circuits, protection devices
- Superb understanding of creepage and clearance analysis and standards (ie IEC, UL etc.)
- Ability to model resistive losses, run current density analysis to optimize busbar geometry and sizing to meet system performance and mass requirements
Preferred Qualifications
- Familiar with electrical standards (NEC); experience with battery and power conversion standards (UL9540, UL1741) a plus
- Leadership, the ability to mentor, and well-developed communication, collaboration, and engagement skills working with a variety of teams and stakeholders
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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.
