Form Energy Begins Expansion of Form Factory 1 to Increase Manufacturing Capacity
Form Energy has started expanding its Weirton, West Virginia, manufacturing facility to increase production of iron-air batteries, with completion expected by late 2025. The project aims to boost annual output to 500 megawatts and add at least 750 jobs by 2028.
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Form Energy has begun construction on an expansion of Form Factory 1 in Weirton, West Virginia, to increase manufacturing capacity for its iron-air batteries. The project is scheduled for completion by the end of 2025 and will support the company’s goal of producing 500 megawatts annually by 2028. The expansion will also create additional jobs, with plans to hire at least 750 workers at the facility. Local construction crews, including union laborers, are expected to play a key role in the project’s development.
The expansion is taking place on the site of the former Weirton Steel mill, which operated for decades before closing. Form Energy has preserved parts of the old mill’s Stock Building frame for repurposing, including salvaging scrap steel for artwork and employee spaces. An exhibit in the factory’s lobby, created with the Weirton Area Museum and Cultural Center, showcases historical artifacts and photos from the mill’s history, including planters made from scrap steel by a local carpenter whose father worked at the mill.
Ted Wiley, Co-Founder, President, and COO of Form Energy, highlighted the significance of the expansion in supporting America’s electric grid while honoring the site’s industrial legacy. The company emphasized its commitment to repurposing materials and preserving the history of the Weirton Steel mill, which was once one of the largest steel producers in the world. The exhibit and repurposed materials serve as a cultural nod to the community’s past.
Local leaders, including Weirton City Manager Mike Adams, praised Form Energy’s investment in the community, noting the transformation of a previously underutilized site. The expansion project reflects the company’s broader efforts to revitalize the area while scaling up production. Construction is already underway, marking a step toward the facility’s expanded role in the region’s industrial and economic future.