Sr. Test Engineer, Mechanical Systems

Role Description

Form Energy is hiring a Senior Test Engineer to join our Systems Test organization onsite at Form Factory 1 (FF1) in Weirton, West Virginia. In this role, you will be the primary on-site mechanical test engineering owner responsible for the execution, hands-on root-cause analysis, and telemetry data reporting across major multi-pack integrated test assets and mechanical subsystems.

You will partner closely with the California-based mechanical test engineering organization to co-develop, refine, and translate mechanical, structural, fluidic, and thermal requirements and DFMEAs into rigorous, executable test plans following the Test @ Form process. Onsite in Weirton, your primary focus will be leading physical test execution (including structural loading, transportation vibration, seismic simulation, pressure/leak verification, and fluidic flow characterization), triaging mechanical anomalies, and validating data integrity to feed actionable results back to design and test engineering teams. Relocation assistance is available.

What you'll do:

• Partner closely with the California-based mechanical test engineering team to translate mechanical, structural, and fluidic requirements and DFMEAs into actionable test plans (VERTs/VALs) following the Test @ Form process.
• Lead physical test execution across module stands, auxiliary skids, and multi-pack test assets in Weirton, WV.
• Execute campaigns covering structural loading, transportation vibration/shock, seismic simulation, and fluidic handling loops (electrolyte, N2 purge, hydrogen dilution, and air-handling circuits).
• Collaborate with partnering design and test engineers to deploy and calibrate mechanical test rigs, pressure decay fixtures, strain gauge layouts, accelerometers, load cells, and flow/pressure instrumentation.
• Act as the primary on-site triager when mechanical or fluidic anomalies occur (e.g., seal leaks, structural deflection, flow restrictions, or mechanical fatigue), applying pressure decay, dye testing, and structural inspection techniques to isolate root causes.
• Process raw mechanical telemetry (strain, acceleration/vibration spectra, fluid flow rates, differential pressures, temperatures) to validate data integrity and synthesize findings into clear, actionable test reports for CA and WV engineering stakeholders.
• Enforce strict mechanical/fluidic safety protocols, pressure vessel safety standards, Lock-Out/Tag-Out (LOTO), chemical handling guidelines, and 5S standards in the laboratory.

What you'll bring:

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Systems Engineering, Mechatronics, or a related technical discipline.
• 5+ years of hands-on experience in mechanical test engineering, structural/vibration testing, fluidic system validation, or physical laboratory testing (highly valued within battery systems, EV, aerospace, grid-scale storage, or heavy industrial sectors).
• Proven experience deriving mechanical and fluidic test plans directly from structural/fluid requirements, CAD/FEA/CFD design intent, and DFMEAs.
• Strong technical background in fluid mechanics, piping/tubing manifolds, pumps, valves, pressure regulation, and gas dilution/purging systems.
• Direct familiarity with structural loading, vibration/shock testing standards (e.g., ISTA, ASTM, MIL-STD), and seismic testing methodologies.
• Practical expertise with mechanical instrumentation: strain gauges, load cells, accelerometers, pressure transducers, flow meters, and thermal cameras.
• Proficiency using data acquisition systems and analysis tools (Python, MATLAB, LabVIEW, or similar suites).
• Familiarity with Atlassian toolsets (JIRA, Confluence) and requirements management platforms (e.g., Jama)

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

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.