Senior Mechanical Engineer – Thermal & Air Systems

Senior Mechanical Engineer – Thermal & Air Systems

Alameda, CA

We are looking for a hands-on Senior Mechanical Engineer to join our Core Technology team, focused on the design and development of hot air handling systems for high-temperature energy storage applications. This role is central to delivering robust ducting networks, plenum assemblies, dampers, louvers, and associated air-distribution equipment that operate reliably at elevated temperatures. The ideal candidate combines analytical depth with design and assembly knowledge, and a passion for solving complex thermal-fluid engineering challenges.

Responsibilities include but are not limited to:

• Lead the mechanical design ofhot airducting systems, plenum assemblies, and air distribution componentsoperatingat temperatures up to 1000 °C.
• Design, specify, andvalidatedampers (isolation, control, backdraft, and diverter types) and louvers for high-temperature service, including actuatorselectionand leakage performance requirements.
• Design plenum assemblies, transition pieces, expansion joints, and support structures that accommodate thermal growth whilemaintainingstructural integrity.
• Define subsystem requirements and develop verification and validation (V&V) plans aligned with system-level performance, safety, and operational goals.
• Prepare technical documentation—drawings, specifications, and engineering calculations—for internal teams, fabricators, and external stakeholders.
• Perform thermal and fluid analyses to identify key design drivers; use FEA where required to confirm mechanical performance under thermal and pressure loads.
• Lead and contribute to FMEA activities toidentifyand mitigate risk; develop and execute test strategies, including design of experiments (DOE), tovalidatesystem performance and reliability.
• Support prototyping,test plans,vendor qualification, and iterative development across high-temperature metallic and insulated duct assemblies.
• Lead the air circulation sub-system for product development of Rondo’s current and next generation product line. Follow Rondo product development phase gate process, lead Rondo product developmentreviewsandmaintainphase gate documentation.
• Develop top level system architecture for Rondo Heat Battery Air Management and Heat Delivery systems.
• Lead andparticipatein design reviews, schedule planning, and cross-functional progress reporting to drive program execution.
• Utilize CAD and PLM tools (Solid Works preferred) for design, documentation, and configuration control of air-system components.
• Collaborate with manufacturing, construction, and supply chain teams to improve quality,establishprocess controls, and resolve root causes of field failures.
• Develop duct sizing, routing, and layout using first-principles pressure drop calculations and 1D flow network analysis, ensuring compliance with velocity, pressure, and thermal expansion requirements.
• Solve coupledmultiphysicsproblems involving heat transfer (conduction, convection, radiation), fluid flow, and structural behavior in high-temperature air systems.

• Bachelor’s or Master’s degree in Mechanical Engineeringora related discipline.
• 7+ years of engineering experience with a focus on air systems, industrial gas handling, or high-temperature process systems; energy industry experience preferred.
• Proven track recordof taking designs from concept through fabrication and commissioningfor one or multipleof followingsystems:
  
  Dampers, actuators, louvers, ducts, plenum, furnace
• Experience with high temperatureequipment design.
  
  Experience with high-temperature materials: stainless steels, Inconel, refractory linings, ceramic fiber insulation, and high-temperature expansion joint materials.
• Knowledge of relevant codes and standards (e.g.,API, ASME, NFPA, applicable EN standards for industrial ducting and pressure equipment).
• Strong cross-functional collaboration and communication skills; ability to work effectively with construction, commissioning, and operations teams.
• Demonstrated commitment to engineering rigor, quality documentation, and schedule execution.
• Track recordof driving cost reduction through design optimization and…