Senior Mechanical Engineer - High-Voltage Design

Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company. We’re revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what’s possible, we’re giving clean energy a whole new form! 

In recent years, Form Energy has earned a number of accolades, including being named by TIME as a “Best Invention”, MIT Technology Review as a “Top Climate Tech Company To Watch”, and Fast Company as “One of the Next Big Things In Tech”. We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States and production of our iron-air batteries is underway at our first high-volume manufacturing facility in West Virginia.

Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing -  might be the most exciting moment in the company’s history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better.

Feeling energized to make a meaningful impact on the world? Then keep reading - you’ve come to the right place.

Role Description

Form 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 High Voltage 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.)

• Design and optimize high voltage joints for reliability and performance (bolted, welded, 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 6+ years, or master's with 4+ years of relevant experience developing medium to high volume products.

• Proven experience with electromechanical design of power distribution systems, electrical circuits, and protection devices. Ability to model resistive losses, size and optimize busbar geometries, and design for high voltage creepage and clearance (ie IEC, UL etc.).

• Expertise in engineering analysis (thermal, CFD, structural, 1D modelling, etc), cost modelling, and optimizations, and evaluation of system-level trade-offs to inform architecture studies and design decisions.

• Strong mechanical and electrical engineering fundamentals, GD&T, and first principles hand calculations. Experienced user of CAD (SolidWorks, NX, etc.).

• Direct experience with medium-to-high-volume manufacturing, fabrication, and prototyping techniques; tolerance stack-up analysis; tight-tolerance component design; and DFM/DFA principles.

• 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)

• Strong leadership, mentoring, communication, collaboration, and stakeholder engagement skills, with a proven ability to work effectively across multidisciplinary teams.

#LI-Onsite

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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. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.

If you may require reasonable accommodations to participate in our interview process, please contact [email protected]. Requests for accommodations will be treated with discretion.

Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.