Sr. Test Engineer, Electrical & Software Systems

Form Energy is hiring a Senior Test Engineer to join our Systems Test organization. In this role, you will be a key contributor focused on driving robust test plans and execution strategies derived directly from electrical, software, and controls requirements, as well as Design Failure Mode and Effect Analyses (DFMEAs). You will oversee the electrical and software test elements across cell, module, and major multi-pack integrated test assets.

These systems serve as the cornerstone of our validation strategy, verifying our custom battery management systems (BMS), power electronics, industrial communication networks, plant control algorithms, and overall system integration.

You will be directly responsible for translating electrical, software, and controls requirements into comprehensive test procedures (VERTs/VALs), executing tests on physical hardware, triaging software/hardware faults, and validating data integrity across test campaigns. The ideal candidate pairs high technical capability in electrical test engineering and software/controls verification with a rigorous first-principles troubleshooting mindset. Relocation assistance is available.

Lead the review and translation of electrical, software, and controls requirements and DFMEAs into actionable, rigorous test plans and verification test requirements following the Test @ Form process.

Drive test plan execution and validation for electrical and software elements across cell, module stands and integrated multi-pack assets.

Validate BMS hardware, firmware releases, plant software, control algorithms, and safety interlock state machines.

Execute tests focused on industrial communication protocols (CAN, Modbus, Ethernet, EtherCAT), verifying signal mapping, bus traffic, latency, and telemetry robustness.

Act as the primary hands-on triager when test anomalies occur, analyzing board schematics, harness connections, firmware logs, and control scripts to isolate root causes.

Process and review raw telemetry, software logs, and high-speed electrical data streams to validate data integrity and synthesize findings into clear test reports.

Manage lock-out/tag-out (LOTO) requirements for electrical safety, verify electrical interlocks, and maintain 5S standards within high-energy laboratory environments.

Bachelor’s degree in Electrical Engineering, Computer Engineering, Systems Engineering, Software Engineering, Mechatronics, or a related technical discipline.

5+ years of hands-on experience in electrical test engineering, software/firmware test validation, or systems integration (highly valued within battery systems, EV, aerospace, grid-scale storage, or heavy industrial sectors).

Proven experience deriving test plans, test cases, and verification metrics directly from system requirements, control ConOps, and DFMEAs.

Strong practical familiarity with low-voltage/high-voltage electrical schematics, harness design, board-level testing, and power electronics.

Proficiency writing, editing, or executing automated test scripts using Python, MATLAB, or LabVIEW.

Strong understanding of standard industrial network protocols (CAN, Modbus, Ethernet, EtherCAT) and network telemetry troubleshooting.

Familiarity with Atlassian toolsets (JIRA, Confluence) and requirements management systems (e.g., Jama).

This role is based at Form Factory 1 in Weirton, WV—an easy commute from the city of Pittsburgh, PA. This 550,000-square-foot facility is our hub for high-volume battery production and a leader in the new era of American energy manufacturing. Relocation assistance is available.

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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 [email protected]. 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.