Mechanical Test Engineer

Mechanical Test Engineer

The Mechanical Test Engineer designs, develops, and validates complex mechanical test beds and environments that accurately simulate real-world operating conditions for advanced battery energy storage systems. This role focuses on mechanical and thermal systems, including HVAC, thermal management, hydrogen and electrolyte management, and air-handling systems for battery components. The engineer collaborates closely with cross-functional teams to translate high-level testing requirements into robust mechanical hardware that identifies failure modes early in the development cycle, directly supporting the scaling of innovative battery technology in a fast-moving organization with a mission-driven culture.

Responsibilities:

• Lead the mechanical design of complex test beds from initial concepts through detailed CAD, fabrication, and assembly, ensuring they meet performance, safety, and reliability requirements.
• Design HVAC systems, thermal management systems, hydrogen management systems, electrolyte management systems, and air-handling systems tailored for battery energy storage system (BESS) components.
• Develop test environments that accurately simulate real-world operating conditions for battery packs and auxiliary systems, including pumps, manifolds, and power electronics.
• Translate high-level test requirements into functional mechanical hardware that enables early detection of failure modes and supports design validation.
• Perform airflow analysis, including fan and blower selection, ducting design, and optimization of air-handling paths to achieve desired thermal performance.
• Conduct piping calculations and fluid systems design to ensure proper flow, pressure, and distribution within test setups and supporting mechanical systems.
• Carry out materials stress analysis for high-temperature applications to ensure structural integrity and durability of test fixtures and components.
• Create detailed 3D models and engineering drawings using Solid Works, including assemblies, subassemblies, and fabrication-ready documentation.
• Perform fluids analysis and CFD studies to evaluate and optimize fluid flow and thermal behavior in mechanical and thermal systems.
• Collaborate closely with Electrical, Controls, and Chemical Engineers to integrate sensors, actuators, and data acquisition hardware into mechanical designs.
• Support derisking and validation activities by iterating on mechanical designs based on test results, failure analysis, and feedback from test and design engineering teams.
• Communicate design intent, technical decisions, and test system performance clearly to cross-functional stakeholders, both verbally and in written form.
• Assist in the assembly, commissioning, and troubleshooting of mechanical test beds and associated systems in an onsite lab or test facility environment.

Essential

Skills:

• Proven experience in mechanical engineering with a focus on mechanical systems and mechanical design.
• Proficiency in Solid Works, including 3D modeling, assembly creation, and detailed drawing generation for fabrication and assembly.
• Experience with fluid mechanics and fluid systems design, including piping calculations and flow distribution.
• Hands-on experience with fluids analysis and CFD (computational fluid dynamics) for evaluating fluid flow and thermal performance.
• Experience in thermal analysis and thermal systems design, including airflow analysis and component specification such as fans and blowers.
• Ability to design and analyze HVAC systems, thermal management systems, hydrogen management systems, electrolyte management systems, and air-handling systems.
• Experience performing materials stress analysis, particularly for high-temperature environments and components.
• Familiarity with integrating electronics, sensors, actuators, and data acquisition hardware into mechanical designs.
• Strong communication skills, with the ability to work effectively in cross-functional teams and explain complex mechanical concepts clearly.
• Capability to take designs from conceptual CAD through to fabrication, assembly, and validation in a test environment.

Additional Skills &

Qualifications:

• Experience designing test beds or test environments for battery packs, pumps, manifolds, and power electronics.
• Experience in supporting derisking and validation activities by translating high-level testing requirements into practical mechanical hardware.
• Exposure to battery energy storage systems (BESS) or related energy, power, or thermal management applications.
• Experience working closely with Electrical, Controls, and Chemical Engineers on integrated systems.
• Interest in contributing to the scaling of breakthrough battery technology and working in a fast-moving, mission-driven organization.

Work Environment:

This role is based onsite in Berkeley in a hands-on engineering and test facility environment. The Mechanical Test Engineer works directly with physical test beds, mechanical assemblies, and laboratory equipment, collaborating closely with design,…