Senior Mechanical Engineer

Responsibilities

• Lead concept development, design trades, and down-selection decisions for mechanical subsystems across water purification, electrolyzer systems, and post-production hydrogen purification.
• Own 3D CAD design of complex parts and assemblies, including sheet metal, plastics, insulation, seals, connectors, and fasteners.
• Review and develop process flow diagrams, P&IDs, and mechanical design documentation.
• Perform first-principles calculations for fluid, thermal, and structural system sizing and performance.
• Integrate high-voltage power electronics and low-voltage control, sensing, and communications systems into mechanical enclosures.
• Design packaging for bus bars, power modules, and high-current connectors, ensuring insulation, creepage and clearance compliance, and thermal management.
• Design and validate cooling technologies, including heat exchangers and forced-air systems, for electrolyzer stacks and electrical components.
• Ensure enclosure designs meet applicable UL, IEC, and NFPA electrical safety standards.
• Define and manage interface control documents between mechanical and electrical subsystems.
• Apply Design for Manufacturability and Design for Assembly principles with manufacturing partners from concept through production release.
• Create and maintain Balance-of-Plant documentation, including bills of materials, P&IDs, and fluid system specifications.
• Design and validate gas and water piping systems, including pressure ratings, material compatibility, and leak testing.
• Develop test plans and lead laboratory testing and validation activities.
• Maintain PLM documentation, including bills of materials, engineering drawings, design calculations, and FMEAs.

Requirements

• Bachelor's degree in Mechanical Engineering or equivalent.
• 6+ years of relevant experience in commercial product design and development.
• Strong understanding of statics, mechanics, materials science, heat transfer, thermodynamics, and fluid dynamics, with the ability to perform hand calculations.
• Experience taking mechanical designs from concept through prototype builds, manufacturing release, and production.
• Proven DFM/DFA experience with manufacturing partners.
• Experience packaging and integrating electromechanical systems containing high- and low-voltage components.
• Proficiency with 3D CAD; SolidWorks strongly preferred.
• Experience with thermal and structural FEA tools.
• Hands-on experience in laboratory, shop-floor, and test-rig environments.
• Experience creating GD&T-compliant 2D fabrication drawings using ASME Y14.5.

Nice-to-Haves

• Master's or Ph.D. in Mechanical Engineering or a related field.
• Experience with PEM electrolysis, fuel cells, or related electrochemical systems.
• Experience with hydrogen, oxygen, nitrogen, or other high-purity gas systems, including pressure management, material selection, and leak testing.
• Experience with water purification technologies such as deionization, ultrafiltration, or reverse osmosis.
• Experience with post-production gas purification.
• Multi-physics or CFD simulation experience with ANSYS Fluent, COMSOL, or similar tools.
• Familiarity with UL 508A, IEC 60204, and NFPA 70E.
• Experience with PLM systems for bill-of-materials and drawing management.

Compensation and Benefits

• Competitive salary and equity compensation commensurate with experience.
• Fully paid medical, dental, and vision coverage.
• Paid sick days and vacation.
• In-office lunches.