Senior Staff Engineer, Hydrogen Safety Architecture at Form Energy — Berkeley, CA

Role Description

The Fluid Systems Mechanical Engineering team at Form is focused on architecting and designing the multiple gas and liquid systems that traverse our battery cell, module, and full pack, forming the foundation of our innovative utility-scale multi-day energy storage system. Within the Fluid Systems team, our Hydrogen System is crucial to the reliable operation of our iron-air batteries, because it safely manages hydrogen that is generated during battery use. We strive to deliver designs that are optimized for performance, quality, reliability, and cost for high-volume manufacturing at Form Factory.

We are seeking a Senior Staff Engineer, Hydrogen Safety Architecture to serve as the ultimate technical authority on hydrogen safety, mitigation, and compliance for our multi-day energy storage systems. In this role, you will bridge the gap between complex chemical dynamics and robust mechanical engineering. You will own the safety architecture of our hydrogen venting and leak mitigation systems, oversee broader fluidics subsystems, and act as the principal interface between engineering and compliance.

This is a high-impact, senior-level role requiring a deep mechanical engineering foundation and a proven track record of successfully commercializing products that generate, utilize, or transport hydrogen.

If this sounds like the right position for you, apply now! This opportunity will help shape and scale our multi-day energy storage system, contributing to the growth of a fast-moving company with breakthrough technology and an incredible mission, contributing to a sustainable future!

Relocation assistance is available.

What you'll do

• Author, own, and sign off on Hazardous Zone Analyses (HZA) for our multi-megawatt battery installations.
• Architect and design cutting-edge mechanical systems for hydrogen venting, dilution, and leak mitigation, ensuring strict adherence to global safety and compliance standards.
• Oversee the architectural design of adjacent fluids subsystems (including thermal management, O2 airflow supply, and electrolyte delivery) to optimize cross-functional performance and eliminate system-level risks.
• Own and manage the system P&IDs from conceptual design through to production-ready documentation.
• Establish, manage, and execute comprehensive analysis (e.g., CFD, dispersion modeling) and validation strategies to verify that all hardware meets performance requirements and safety standards.
• Serve as the primary technical liaison with internal compliance engineers, AHJs (Authorities Having Jurisdiction), and external regulatory bodies to secure product certifications.
• Define System Theory and Concept of Operations for Controls and Electrical implementation.

What you'll bring:

• Bachelor’s in Mechanical Engineering, Chemical Engineering, or a highly related technical field.
• A licensed Professional Engineer (PE) is preferred.
• 8+ years in industry, including 3+ years of experience commercializing safety solutions for products that actively generate or handle hydrogen (e.g., electrolyzers, fuel cells, industrial chemical systems, or advanced battery technologies).
• Deep working knowledge of relevant safety standards such as NFPA 2, NFPA 69, IEC 60079, UL9540, UL 1973, or equivalent international codes.
• Proven ability to manage complex mechanical architectures, negotiate trade-offs between fluid, thermal, and electrical subsystems, and maintain rigorous P&ID version control.
• Exceptional communication skills with a demonstrated ability to influence cross-functional engineering teams, simplify complex technical risks, and confidently interface with external regulatory bodies.

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