{"id":231449,"url":"https://alion.io/job/form-energy-senior-mechanical-engineer-high-voltage-design","title":"Senior Mechanical Engineer, High-Voltage Design","company":{"id":58579,"name":"Form Energy","domain":"formenergy.com","url":"https://alion.io/company/form-energy","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Ashby","truth_index":{"grade":"A","score":86,"open_postings":23,"ghost_share":0,"stale_share":0.348,"repost_share":0,"time_to_fill_p50_days":71,"computed_at":"2026-11-05T05:54:30Z"}},"role":"Energy","role_family":"Energy","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Berkeley, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":128662,"max":168844,"currency":"USD","period":"year","gross":null,"usd_annual":168844},"salary_estimate":null,"experience_years_min":4,"visa_sponsorship":false,"relocation_package":false,"has_equity":true,"technologies":[{"name":"GD&T","optional":false},{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-09-03T18:10:09Z","employer_posted_date":"2026-09-03","last_verified_at":"2026-11-05T12:53:29Z","board_verified":true,"closed_at":null,"days_open":62,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":62},"description":"Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company. We’re revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what’s possible, we’re giving clean energy a whole new form!\nIn recent years, Form Energy has earned a number of accolades, including being named by TIME as a “Best Invention”, MIT Technology Review as a “Top Climate Tech Company To Watch”, and Fast Company as “One of the Next Big Things In Tech”. We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States and production of our iron-air batteries is underway at our first high-volume manufacturing facility in West Virginia.\nWorking for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing - might be the most exciting moment in the company’s history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better.\nFeeling energized to make a meaningful impact on the world? Then keep reading - you’ve come to the right place.\nRole Description\nForm Energy’s HV & LV Design Team is seeking a Senior level Mechanical Design Engineer to drive the HV requirements, design, simulation and testing of our Gen 2 and beyond power systems for clean energy delivery from batteries to the grid. You will be responsible for designing electro-mechanical sub-assemblies that will deliver power and control signals to various auxiliary systems within the battery enclosure. You will take designs from concept to production in a fast paced environment while ensuring quality and reliability through rigorous tests. This role requires collaboration with various engineering teams, making it an exciting opportunity to contribute to cutting-edge technology at a dynamic company with a remarkable mission.\nWhat you'll do:\nProvide technical leadership and mentorship within a multidisciplinary engineering team, fostering the growth and problem-solving skills across team members\n\nOwn the electromechanical design of Form’s battery products, including high voltage distribution (busbars and cables), isolation, grounding, harnessing, connectors, overmolded bussing, plastic and metal enclosures for various PCBA and electrical assemblies, and safety and interlocks (contactor, fuses etc.)\n\nAddress challenges related to electronics packaging, encompassing tasks such as electrical isolation, sealing, thermal regulation, interconnection & shock and vibration mitigation\n\nLeading RCAs and cross-functional interface design\n\nMechanical design analysis including thermal, structural, design for assembly, and design for test\n\nOwn the design from conception through all of its iterations to mass-production\n\nCreate drawing packages and manufacturing instructions for parts and assemblies\n\nDesign and develop electromechanical and electrical systems in support of test stand safety, improvements, and simplification\n\nWhat you'll bring:\nA degree in Mechanical/Mechatronics Engineering or a related field; bachelor's with 4+ years, or master's with 3+ years of relevant experience developing medium to high volume products\n\nProven experience with electrical and mechanical design and proficiency in CAD (SolidWorks, NX, etc.)\n\nExpertise in cost modeling, multi-physics simulations (e.g., thermal, CFD, structural), and optimizations, with the ability to navigate system-level trade-offs and integrate them into architecture studies\n\nStrong mechanical and electrical engineering fundamentals, GD&T, and first principles hand calculations.\n\nDirect experience with high-volume manufacturing, fabrication, and prototyping techniques; experience with tight-tolerance, component design for harsh environments, DFM/DFA.\n\nSolid understanding of power distribution, electrical circuits, protection devices\n\nSuperb understanding of creepage and clearance analysis and standards (ie IEC, UL etc.)\n\nAbility to model resistive losses, run current density analysis to optimize busbar geometry and sizing to meet system performance and mass requirements\n\nPreferred Qualifications\nFamiliar with electrical standards (NEC); experience with battery and power conversion standards (UL9540, UL1741) a plus\n\nLeadership, the ability to mentor, and well-developed communication, collaboration, and engagement skills working with a variety of teams and stakeholders\n\n#LI-Onsite\n#LI-TR1\nHumanity 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. \nWhen 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. \nTo build America’s energy future, we need everyone at the table. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.\nIf you may require reasonable accommodations to participate in our interview process, please contact . Requests for accommodations will be treated with discretion.\nForm Energy is committed to maintaining the privacy of our applicants. 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