Senior Quality Engineer at Form Energy — Weirton, WV

Role Description

We are hiring a Senior Quality Engineer to serve as the quality engineering owner for our Electrode manufacturing area. You will develop quality processes and methodologies, lead cross-functional teams, and partner with Design Engineering, Manufacturing Engineering, Suppliers, and Operations to address quality, reliability, and manufacturability challenges across the electrode production process. This is a hands-on individual contributor role covering the full product development lifecycle — from early R&D and validation testing through pilot builds and high-volume production. You will be a key contributor to Form Energy's Quality Team, ensuring that electrode products consistently meet customer and internal requirements. Relocation assistance is available.

What you'll do

• Own and drive quality processes and documentation for electrode manufacturing, including Control Plans, PFMEAs, and inspection/test methods
• Lead change management and support execution of process development experiments across batch powder mixing, thermoplastic polymer processing, heat treatment, epoxy curing, and continuous web handling operations
• Regularly review and revise PFMEAs and Control Plans to reflect process changes and lessons learned
• Lead identification and resolution of manufacturing quality issues, including root cause analysis and corrective actions
• Drive continuous improvement activities in partnership with Design/Manufacturing Engineering and external Suppliers
• Lead Statistical Process Control (SPC) activities and apply critical thinking to systematically reduce variation across electrode manufacturing unit operations
• Lead non-conforming material control activities for electrode materials and sub-components
• Develop and apply material characterization and testing protocols — including TGA, DSC, and powder characterization methods — to support process control and qualification
• Collaborate proactively with process and product development teams to identify, assess, and mitigate quality risks before they reach production

What you'll bring:

• 3–10 years of quality engineering experience in a manufacturing environment
• Bachelor's degree in Materials Science, Chemical Engineering, Mechanical Engineering, Electrical Engineering, or a related field; advanced degree a plus
• Solid experience with SPC, PFMEAs, and Control Plans
• Strong aptitude with electronic test and measurement systems
• Proficiency in reading and interpreting mechanical drawings and wiring diagrams
• Structured problem-solving (8D) and strong statistical skills including DOE, Process Capability (Cpk, Ppk), etc.
• Proficiency with data analysis tools such as JMP, R, Minitab, or equivalent
• Ability to manage, synthesize, and interpret complex data sets
• Familiarity with one or more electrode manufacturing processes such as batch powder mixing, thermoplastic polymer processing, metal heat treatment, epoxy curing, or web handling/continuous manufacturing
• Experience with materials characterization techniques such as TGA, DSC, or powder characterization (particle size distribution, flowability, etc.) is a plus

Where you'll work:

#LI-Onsite

#LI-JM2