Mechanical Engineer

Job Title:

R&D Mechanical Engineer

Job Description

This R&D Mechanical Engineer role focuses on the development of advanced battery power module technology, with an emphasis on mechanical design, thermodynamics, fluid flow, and structural analysis. You will play a key role in ensuring performance, reliability, and cost-effectiveness by contributing to mechanical design, structural and fluidic analysis, testing and validation, prototyping, and specification creation. This position is ideal for someone who is passionate about sustainability and clean energy, thrives in a fast-paced entrepreneurial environment, is self-motivated, and enjoys working on disruptive, cutting-edge technology.

Responsibilities

+ Serve as a contributor to the mechanical design of stack and subsystem hardware, including manifolds, flow fields, plates, frames, enclosures, and seals, using 3D CAD tools and rigorous design control practices such as models, drawings, specifications, bills of materials, and GD&T.

+ Analyze and optimize thermal and fluid performance, as well as structural integrity under pressure, temperature, vibration, and thermal cycling, using FEA and CFD, and translate insights into robust design updates.

+ Engineer components and assemblies for manufacturability and reliability (DFM, DFA, DFR) across casting, machining, plastics processes such as injection molding and extrusion, plastics welding, and sealing processes including welding, adhesives, and gaskets.

+ Select materials compatible with electrolytes and other corrosive environments, and address creep, fatigue, and stress-relaxation mechanisms with appropriate safety margins and life predictions.

+ Develop validation plans and correlate models to test results by defining test articles and fixtures, analyzing test data, closing the loop with simulations, and driving root-cause analysis and corrective actions.

+ Collaborate closely with engineering and supply chain teams to convert performance targets into durable, cost-effective designs that are ready for production.

+ Continuously improve cost, reliability, and serviceability of designs while maintaining safety, compliance, and quality standards.

+ Create and maintain detailed engineering documentation, including parametric 3D models, detailed drawings, and BOMs, in alignment with design control requirements.

+ Support quality efforts by defining and verifying critical-to-function and critical-to-quality features through appropriate inspection methods.

+ Participate in prototyping, testing, and validation activities to advance hardware from concept through prototype, pilot, and into production.

Essential Skills

+ B.S. in Mechanical Engineering or a closely related discipline.

+ 5+ years of experience in mechanical design and analysis of complex fluid or electrochemical systems, or an equivalent combination of graduate and industry experience.

+ Proficiency in 3D CAD tools such as Inventor, Solid Works, or equivalent, including parametric design, detailed drawings, and bills of materials.

+ Strong foundation in thermodynamics, fluid mechanics, and solid mechanics, with hands-on experience in FEA and CFD.

+ Experience performing tolerance stack-ups and applying rigorous design control practices.

+ Demonstrated ability to develop detailed engineering drawings using GD&T principles per ASME Y14.5.

+ Strong understanding of quality inspection methods to accurately define and verify critical-to-function and critical-to-quality features.

+ Experience designing for corrosive or reactive fluids and hermetic sealing, including welds, adhesives, and gaskets.

+ Proven track record of cross-functional execution from concept to validated hardware, including progression from prototype to pilot to production.

+ Clear and concise communication skills, with the ability to work in a self-directed manner and manage multiple design work streams simultaneously.

+ Ability to lift up to 50 lbs unassisted in a lab or shop environment.

+ Ability to follow job-required standards and safety protocols according to predefined processes.

+ Ability to wear and properly use personal protective equipment in accordance with OSHA rules and regulations.

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