In September of 2020, I was the third mechanical engineer on the product development team. I joined Form when the company was around 50 people, and it has since raised over $1B and employs over 800 people.

In my first days at Form, our standard cell was the size of a tupperware, and nothing had been built at scale. At the time, the biggest risk to our product was scaling the height of the battery to the full meter the product requirements demanded, and the riskiest electrode to scale at this height was the air cathode.

The first thing I built as an engineer at Form was a PVC pipe stack to test the air cathode under full hydrostatic pressure, and I grew to own the product design of the air cathode assembly manufactured in hundreds of units by the time I left, with ramp-up plans for thousands.

In this role, I was responsible for concept generation to execution of machined and injection molded parts that integrate the cathode active material into the complex electrochemical assembly that comprises a cell in our battery system.

I worked with the cathode R&D team to determine requirements for the active material, the systems team air delivery at the enclosure level, and engineers on the cell and module teams to make sure our parts fit and assemble well together.

Much of what I worked on is confidential and protected IP, so this page is mostly for telling that abridged story and showing just a few images.