Role DescriptionIn this role, you will own the end-to-end industrialization journey for plastic components-from the first sketch to high-volume production and ongoing sustaining support. You will be the bridge between our Design Engineering teams and our global supply base, ensuring that every part is designed for manufacturability (DFM) and produced under rigorous quality controls. You will not just launch products; you will implement the systems that ensure our suppliers deliver on time, meet capacity, and maintain world-class quality standards
Relocation assistance is available.
What you'll do:- Lead the comprehensive technical lifecycle of thermoplastic components. Provide critical up-front manufacturing feasibility feedback during design concepts, spearhead technical evaluations for supplier selection, drive multi-stage tooling qualification (ex. T0 - T2), and establish permanent on-site process controls.
- Own and track the minimum supplier deliverables per build phase. Ensure tooling, manufacturing lines, and part accuracy mature in tight lockstep with program timelines to proactively eliminate downstream line down risks.
- Collaborate deeply with Design Engineering to conduct robust 3D DFM reviews and evaluate injection molding simulation packages (e.g., Moldflow). Proactively catch and eliminate potential manufacturing failure modes such as severe knit lines, flash, sink marks, or dimensionally unstable warp before tools are kicked off.
- Champion the phased rollout of Advanced Product Quality Planning (APQP) with supplier teams. Establish, review, and approve robust supplier Process Flow Diagrams (PFD), Process FMEAs (PFMEA), and formal Control Plans to systematically isolate and mitigate high-severity manufacturing risks.
- Function as the technical gatekeeper for out-of-specification components. Issue and manage Supplier Corrective Action Requests (SCAR), driving suppliers through rigorous root cause analysis (8D, 5-Whys) to validate permanent corrective actions.
- Audit supplier process capability metrics for defined special characteristics to ensure the process remains statistically stable over long production cycles. Approve supplier PPAP submissions to guarantee that inspection systems yield highly reliable data.
What you'll bring:- Bachelor's degree in Plastics, Mechanical, or Manufacturing Engineering.
- 5+ years of experience in New Product Introduction (NPI), manufacturing, or quality engineering.
- Deep Foundational knowledge of thermoplastic molding processes (injection molding, ultrasonic welding, etc.) and secondary operations like painting or assembly.
- Familiarity with quality tools such as SPC (Statistical Process Control), Root Cause Analysis (8D), and Geometric Dimensioning and Tolerancing (GD&T).
- Proven capability to read and interpret complex 2D drawings using Geometric Dimensioning and Tolerancing (GD&T) principles per ASME Y14.5. Proficiency with 3D CAD platforms to interrogate geometries, analyze assembly stack-ups, and evaluate tooling clearances.
- Excellent communication and technical authority to hold international partners accountable to strict delivery schedules and quality indices while simultaneously fostering cooperative, long-term technical relationships.
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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.
