Senior Mechanical Design Engineer, Fluids Analysis

The role

You will own physics-based modeling to inform architectural strategies and design details for Electrolyte, Thermal, Hydrogen, and Air Delivery Systems. You will build CFD and transient thermal modeling strategies to optimize 100-hour iron-air battery systems.

What you will do

• Build high-fidelity computational fluid dynamics (CFD) and transient thermal modeling strategies.
• Validate and anchor numerical physics-based models against empirical data.
• Support the development of automated simulation and optimization workflows.
• Partner with electrochemical, mechanical, and power electronics teams to resolve thermal-fluid anomalies.
• Select simulation methodologies, mesh structures, and boundary condition assumptions.
• Drive the standardization of internal modeling workflows and establish peer design reviews.
• Identify limitations in physics-based toolsets and build customized tools.

Required qualifications

• Bachelor's degree and 5+ years of related work experience, or a Master's degree and multiple years of experience, or a PhD with deep focus on thermal-fluid sciences and some industry experience.
• Deep technical expertise in commercial computational fluid dynamics codes and meshing software, such as Ansys Fluent, Star-CCM+, or Comsol Multiphysics.
• Strong foundational knowledge of conjugate heat transfer, fluid dynamics, multiphase flow, and closed-loop cooling systems.
• Applied experience using scripting languages like Python or MATLAB to post-process, visualize, and automate massive multi-physics datasets.
• Demonstrated track record of translating complex simulation results into actionable, physical system-level requirements.
• Ability to build formal networks outside your immediate area of expertise.
• Intellectual curiosity.
• Pragmatic problem-solving skills.
• Ability to decompose abstract, highly integrated physical problems into clean, high-performing thermal systems.

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. They are developing multi-day energy storage technology using iron-air batteries.