Sr Mechanical Design Engineer, Structures

Role Description

The Structures Engineering team at Form is responsible for designing the structure, enclosure, and sealing systems that supports and integrates all parts 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 seeking a Sr Mechanical Design Engineer to join our team and contribute to the scaling of our multi-day energy storage system. You'll bring components and assemblies from concept to into mass production, with an emphasis on FEA-driven structural design, weatherproofing, and manufacturability of metal enclosures. You will work cross-functionally with designers and test engineers, interrogating the potential design space and selecting appropriate test methods to validate designs. As a problem solver, you will apply your design knowledge of sheet metal, weldments, and sealing systems to balance structural optimization with design for manufacturability, weight reduction, and cost-down.

What you'll do:

• Create white-page designs that will be the foundation of Form Energy’s next generation battery pack for high volume production
• Perform structural analysis of your designs, utilizing Ansys FEA and hand calcs
• Work closely with test team to initiate test campaigns to establish material libraries for FEA
• Collaborate with test engineers and CAE experts to validate designs through test and FEA correlation
• Present designs, analysis, and test results to broader team and leadership in design reviews
• Perform failure root cause analysis on systems and assemblies
• Travel up to 20% to other Form Energy offices or vendor sites

What you'll bring:

• Bachelor’s Degree in Mechanical Engineering or related field and 4+ years industry experience in mechanical design and structural analysis
• Experience designing complex mechanical structures, using FEA for structural analysis
• Proficiency in computer-aided design (CAD), specifically SolidWorks modeling and drafting using GD&T (ASME Y14.5)
• Experience in component design for mass manufacturing and assembly (DFMA), especially sheet metal, stampings, and weldments
• Sense of urgency and self-driven to hit difficult schedule targets