Role DescriptionWe are hiring a Senior Quality Engineer to serve as the quality engineering owner for our Electrode manufacturing area. You will develop quality processes and methodologies, lead cross-functional teams, and partner with Design Engineering, Manufacturing Engineering, Suppliers, and Operations to address quality, reliability, and manufacturability challenges across the electrode production process. This is a hands-on individual contributor role covering the full product development lifecycle - from early R&D and validation testing through pilot builds and high-volume production. You will be a key contributor to Form Energy's Quality Team, ensuring that electrode products consistently meet customer and internal requirements. Relocation assistance is available.
What you'll do:- Own and drive quality processes and documentation for electrode manufacturing, including Control Plans, PFMEAs, and inspection/test methods
- Lead change management and support execution of process development experiments across batch powder mixing, thermoplastic polymer processing, heat treatment, epoxy curing, and continuous web handling operations
- Regularly review and revise PFMEAs and Control Plans to reflect process changes and lessons learned
- Lead identification and resolution of manufacturing quality issues, including root cause analysis and corrective actions
- Drive continuous improvement activities in partnership with Design/Manufacturing Engineering and external Suppliers
- Lead Statistical Process Control (SPC) activities and apply critical thinking to systematically reduce variation across electrode manufacturing unit operations
- Lead non-conforming material control activities for electrode materials and sub-components
- Develop and apply material characterization and testing protocols - including TGA, DSC, and powder characterization methods - to support process control and qualification
- Collaborate proactively with process and product development teams to identify, assess, and mitigate quality risks before they reach production
What you'll bring:- 3-10 years of quality engineering experience in a manufacturing environment
- Bachelor's degree in Materials Science, Chemical Engineering, Mechanical Engineering, Electrical Engineering, or a related field; advanced degree a plus
- Solid experience with SPC, PFMEAs, and Control Plans
- Strong aptitude with electronic test and measurement systems
- Proficiency in reading and interpreting mechanical drawings and wiring diagrams
- Structured problem-solving (8D) and strong statistical skills including DOE, Process Capability (Cpk, Ppk), etc.
- Proficiency with data analysis tools such as JMP, R, Minitab, or equivalent
- Ability to manage, synthesize, and interpret complex data sets
- Familiarity with one or more electrode manufacturing processes such as batch powder mixing, thermoplastic polymer processing, metal heat treatment, epoxy curing, or web handling/continuous manufacturing
- Experience with materials characterization techniques such as TGA, DSC, or powder characterization (particle size distribution, flowability, etc.) is a plus
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
#LI-JM2
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.
