Description

Role Description
Form Energy is hiring a Senior Process Engineer – Powder Mixing to join our world-class engineering team. Our team is responsible for designing, developing, and scaling cutting-edge electrode manufacturing processes for Form Energy’s Iron-Air multi-day battery.

As a Senior Process Engineer, you will lead the development and optimization of powder mixing operations that are fundamental to the performance and reliability of our electrodes. Your expertise in powder handling, mixing, and scale-up will directly influence the quality, consistency, and throughput of our cathode manufacturing line. You will design and execute experiments, analyze process data, and collaborate with equipment and operations teams to ensure robust and safe scale-up of our mixing systems. This is a unique opportunity to take ownership of a critical process area while shaping the future of a transformative energy storage technology.

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.

Requirements

What you'll do:

• Develop, scale, and optimize powder mixing processes for high-volume electrode manufacturing.
• Define process requirements and partner with equipment engineers to design, specify, and qualify mixing systems.
• Characterize raw material properties (particle size, shape, surface area, flowability) and correlate them with mixing performance and electrode quality.
• Lead experimental trials and data analysis to establish process windows, improve quality, and increase throughput.
• Develop novel test methods to evaluate product quality and inform process window optimization strategies.
• Be a champion for safety while scaling initial process designs to full production volume.

What you'll bring: 

• 5+ years of experience with powder mixing, blending, or related powder handling processes in a manufacturing or pilot environment.
• Demonstrated ability to scale powder processes from lab to production, with a track record of solving complex technical challenges.
• Hands-on experience with industrial mixers (e.g., high-shear, plow, or ribbon mixers) and powder handling equipment.
• Strong foundation in process characterization, statistical methods, and data-driven decision-making.
• Excellent communication and organizational skills, with experience writing process, safety, and quality documentation.
• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a related field.