Senior Mechanical Engineer, FEA Analyst at Form Energy — Berkeley, CA

Role Description

The Mechanical Engineering team at Form is focused on designing the battery cell, module, and system enclosure that forms the foundation of our innovative utility-scale multi-day energy storage system. We strive to deliver designs that are optimized for performance, quality, reliability, and cost for high-volume manufacturing at Form Factory.

We're hiring an experienced Senior Mechanical Engineer, FEA Analyst to join our Mechanical Simulation & Analysis team. This role is intensely focused on executing advanced structural and thermal finite element analysis (FEA) and model validation to proactively ensure our designs are performant, robust, and optimally meet requirements. You will work closely with cross-functional partners such as mechanical design, electrical engineering, cell performance, and system modeling to develop cohesive system architectures. As a key individual contributor, you will drive critical analysis in support of design and build activities on pilot manufacturing lines in Berkeley, CA, and production lines in Weirton, WV. If this sounds like the right role for you, apply now!

This role will be located in our CA offices. This is an exciting opportunity to be part of scaling our multi-day energy storage system at Form and contributing to a sustainable future! Relocation assistance is available.

What you'll do

• Drive Advanced Simulation: Lead the structural and thermal finite element analysis (FEA) and optimization of Form Energy’s iron-air battery components, modules, and massive system enclosures.
• Build High-Fidelity Models: Develop, refine, and maintain complex FEA models (static, dynamic, non-linear, and thermal-structural coupled) to guide design decisions and solve difficult mechanical challenges.
• Correlate & Validate: Execute hands-on model validation and correlation by collaborating with test engineers to design physical tests and interpret empirical data to ensure analytical accuracy.
• Cross-Functional Collaboration: Partner directly with interdisciplinary teams of battery, electrical, chemical, systems, and reliability engineers to optimize designs for performance, cost, and reliability throughout the full development cycle.
• Influence Design: Participate in design reviews, translating complex FEA results into clear, actionable design recommendations for the broader engineering team.

What you'll bring:

• Bachelor's Degree in Mechanical Engineering or related field; with 8+ years of industry experience focused specifically on mechanical simulation and analysis.
• Expert-level knowledge and hands-on capability in structural FEA (static/dynamic, linear/non-linear, fatigue, shock/vibe) and thermal FEA using industry-standard tools (e.g., ANSYS, Abaqus, Nastran).
• Well-developed experience analyzing mechanical systems, heavy assemblies, and components built for high-volume manufacture in a hardware product development company.
• Proven track record of hands-on experience in FEA model validation and correlation with physical test data.
• Solid foundation in mechanical design principles, defining engineering requirements, and implementing FMEA principles.
• Experience in batteries, energy storage, structural enclosures, or other high-power industrial products is a strong plus.
• Excellent technical communication skills, especially the ability to distill complex simulation data into digestible insights for non-analyst partners and cross-functional teams.
• Experience in structural optimization such as performing topology, topography, shape, and sizing optimization to minimize weight while maximizing structural stiffness and durability would be advantageous.

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