Form Energy · 23 hours ago
Staff Process Engineer, Laser Welding
Weirton, WV
Full-time
Onsite
Senior Level, Lead/Staff
7+ years expForm Energy is an American manufacturing and energy technology company focused on revolutionizing energy storage. The Staff Process Engineer, Laser Welding will lead the development and optimization of laser welding processes, playing a critical role in enabling robust joining technologies for battery manufacturing.
BatteryEnergyEnergy StoragePower GridRenewable Energy
Responsibilities
Develop and optimize laser welding processes for dissimilar and similar materials across a variety of thicknesses and joint types
Design and execute Design of Experiments (DOE) to identify optimal process parameters for weld strength, electrical resistance, quality, and repeatability
Conduct in-depth studies of material interactions, weld pool dynamics, heat-affected zones (HAZ), and microstructural evolution
Collaborate with product design teams to ensure weld joint geometry is optimized for manufacturability and performance
Specify, source, and qualify laser welding systems, beam delivery optics, and process monitoring equipment (weld monitoring, pyrometers, cameras etc)
Perform weld characterization and failure analysis using cross-sections, microscopy, tensile/shear testing, and NDE techniques
Develop and implement in-process monitoring and control strategies to ensure real-time weld quality assurance
Author process documentation: weld specifications, control plans, PFMEAs, and standard operating procedures
Support transfer of laser welding processes to pilot or high-volume manufacturing environments
Develop and maintain FMEA, Process specifications, measurement systems GR&R, Control plan, statistical process control (SPC), and quality inspection methods
Mentor, guide, and support team members with your expertise and practical experience
Qualification
Required
Bachelors degree in Mechanical Engineering, Materials Science, Welding Engineering, or a related field
7+ years of hands-on experience in laser welding process development, preferably in a high volume manufacturing environment
Strong understanding of metallurgy, welding metallurgy, and microstructure-property relationships
Proficiency in weld quality inspection methods: optical microscopy, X-ray, ultrasonic, etc
Expertise in statistical understanding and data analysis skills using MATLAB, Python, JMP, or similar tools
Experience welding dissimilar metals (e.g., steel to aluminum, titanium to copper)
Excellent technical writing and communication skills
Benefits
100% of medical, dental, and vision premiums for full-time employees
80% of healthcare premiums for dependents
At least 12 weeks of paid leave for new parents
Up to 20 weeks for birthing parents
Generous vacation policies
Company
Form Energy
Form Energy is an energy technology company that produces electric grids and accelerates the transition to clean energy.
501-1000 employees
H1B Sponsorship
Form Energy has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (29)
2024 (27)
2023 (7)
2022 (3)
2021 (3)
Funding
Current Stage
Late StageTotal Funding
$1.57BKey Investors
Trinity CapitalT. Rowe PriceUS Department of Energy
2024-12-16Debt Financing· $50M
2024-10-09Series F· $405M
2024-08-06Grant· $147M
Leadership Team
Mateo Jaramillo
CEO/co-founder
Marco Ferrara
Co-Founder, Chief Digital Officer
Recent News
EIN Presswire
2025-10-27
2025-10-05
Company data provided by crunchbase