Sr. Test Engineer, Mechanical Systems

The role

The Senior Test Engineer will lead physical test execution and root-cause analysis for mechanical subsystems and multi-pack integrated test assets. This role involves translating requirements into test plans and processing mechanical telemetry data at the Form Factory 1 facility.

What you will do

• Translate mechanical, structural, and fluidic requirements and DFMEAs into actionable test plans.
• Lead physical test execution across module stands, auxiliary skids, and multi-pack test assets.
• Execute campaigns covering structural loading, transportation vibration/shock, seismic simulation, and fluidic handling loops.
• Deploy and calibrate mechanical test rigs, pressure decay fixtures, strain gauge layouts, accelerometers, load cells, and flow/pressure instrumentation.
• Act as the primary on-site triager for mechanical or fluidic anomalies.
• Process raw mechanical telemetry to validate data integrity and synthesize findings into test reports.
• Enforce mechanical/fluidic safety protocols, pressure vessel safety standards, LOTO, chemical handling, and 5S standards.

Required qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Systems Engineering, Mechatronics, or a related technical discipline.
• 5+ years of hands-on experience in mechanical test engineering, structural/vibration testing, fluidic system validation, or physical laboratory testing.
• Experience deriving mechanical and fluidic test plans from structural/fluid requirements, CAD/FEA/CFD design intent, and DFMEAs.
• Technical background in fluid mechanics, piping/tubing manifolds, pumps, valves, pressure regulation, and gas dilution/purging systems.
• Familiarity with structural loading, vibration/shock testing standards (e.g., ISTA, ASTM, MIL-STD), and seismic testing methodologies.
• Practical expertise with mechanical instrumentation: strain gauges, load cells, accelerometers, pressure transducers, flow meters, and thermal cameras.
• Proficiency using data acquisition systems and analysis tools (Python, MATLAB, LabVIEW, or similar suites).
• Familiarity with Atlassian toolsets (JIRA, Confluence) and requirements management platforms (e.g., Jama).

Nice to have

• Experience within battery systems, EV, aerospace, grid-scale storage, or heavy industrial sectors

Benefits

• Competitive salaries
• Stock options
• 100% medical, dental, and vision premiums for full-time employees
• 80% healthcare premiums for dependents
• At least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents)
• Generous vacation policies
• Relocation assistance

About the company

Form Energy is an American manufacturing and energy technology company revolutionizing energy storage with multi-day technology. They are producing iron-air batteries at their high-volume manufacturing facility in West Virginia.