Senior Plastics Design Engineer

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

In 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.

Working 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.

Feeling energized to make a meaningful impact on the world? Then keep reading - you've come to the right place.
Role Description

At Form Energy, the Plastics Engineering team develops robust, high-performance components that meet the demanding requirements of long-duration energy storage. We design for safety, reliability, manufacturability, and scalability—creating parts that perform consistently from prototype through high-volume production.

We're seeking a hands-on Senior Plastics Design Engineer to lead the design and development of plastic components for our next-generation product. This role spans the entire lifecycle—from concept and material selection through design sign-off and production launch. You'll work across multiple plastics manufacturing processes, including injection molding, blow molding, extrusion, rotational molding, and vacuum forming. Success in this role requires strong CAD proficiency (SolidWorks), a deep understanding of polymer material behavior, and solid grounding in DFM, GD&T, and tool design.

You'll participate in internal design reviews, define specifications and testing requirements, and collaborate closely with manufacturing teams, suppliers, and cross-functional partners to ensure quality, cost, and performance goals are achieved. If you're passionate about designing purposeful, manufacturable components that help bring breakthrough energy technology to life, this is an opportunity to make a direct impact on a transformative energy platform.

What you'll do:

• Serve as the Design Responsible Engineer (DRE) for plastic components, ensuring compliance with Form Energy's engineering standards and quality requirements
• Collaborate with cross-functional design teams to ensure seamless system integration and compatibility
• Apply first-principles engineering to guide design decisions and trade-offs
• Lead supplier engagement to transition designs from prototype through high-volume production, ensuring manufacturability and consistency
• Ensure accurate application of GD&T and perform tolerance analyses using RSS methods
• Contribute to and continuously improve Form Energy's plastics design best practices while mentoring junior engineers

What you'll bring:

• Bachelor's Degree in Mechanical Engineering or related field, with 5+ years of dedicated, hands-on experience as a Plastics Engineer, with a proven track record of taking components from concept to high-volume production
• Strong foundation in first-principles design and modeling, with demonstrated success optimizing for performance, cost, and manufacturability
• Proficiency in CAD design; SolidWorks experience preferred
• Hands-on experience in manufacturing environments or with contract manufacturing partners
• Proven ability to optimize mechanical and system-level designs across complex, multidisciplinary architectures
• Demonstrated success guiding products through the full lifecycle with adaptability, sound judgment, and practical, hands-on problem-solving

Humanity 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.
When 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.
To 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.
If you may require reasonable accommodations to participate in our interview process, please contact Requests for accommodations will be treated with discretion.
Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will
never
solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.
Compensation Range: $128.7K - $168K