Process Engineer, Laser WeldingManufacturing Engineering * Weirton, WV On-site

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.

We are hiring a Staff Process Engineer, Laser Welding to lead the development, optimization, and implementation of advanced laser welding processes as we scale up operations in FF1. This role is critical in enabling robust, scalable joining technologies for applications in our assembly area. The ideal candidate will have deep expertise in laser welding fundamentals, metallurgy, and equipment integration, along with strong cross-functional collaboration skills.

This role will be located at Form Factory 1 in Weirton, WV, which is just a short drive outside of Pittsburgh, PA. Relocation assistance is available.

• Develop and optimize laser welding processes for dissimilar and similar materials across a variety of thicknesses and joint types.
• Design and execute Design of Experiments (DOE) to identify optimal process parameters for weld strength, electrical resistance, quality, and repeatability.
• Conduct in-depth studies of material interactions, weld pool dynamics, heat-affected zones (HAZ), and microstructural evolution.
• Collaborate with product design teams to ensure weld joint geometry is optimized for manufacturability and performance.
• Specify, source, and qualify laser welding systems, beam delivery optics, and process monitoring equipment (weld monitoring, pyrometers, cameras etc).
• Perform weld characterization and failure analysis using cross-sections, microscopy, tensile/shear testing, and NDE techniques.
• Develop and implement in-process monitoring and control strategies to ensure real-time weld quality assurance.
• Author process documentation: weld specifications, control plans, PFMEAs, and standard operating procedures.
• Support transfer of laser welding processes to pilot or high-volume manufacturing environments.
• Develop and maintain FMEA, Process specifications, measurement systems GR&R, Control plan, statistical process control (SPC), and quality inspection methods.
• Mentor, guide, and support team members with your expertise and practical experience.

• Bachelors degree in Mechanical Engineering, Materials Science, Welding Engineering, or a related field.
• 7+ years of hands‑on experience in laser welding process development, preferably in a high volume manufacturing environment.
• Strong understanding of metallurgy, welding metallurgy, and microstructure‑property relationships.
• Proficiency in weld quality inspection methods: optical microscopy, X‑ray, ultrasonic, etc.
• Expertise in statistical understanding and data analysis skills using MATLAB, Python, JMP, or similar tools.
• Experience welding dissimilar metals (e.g., steel to aluminum, titanium to copper).
• Excellent technical writing and…