Sr. Mechanical Engineer

Responsibilities

• Lead concept development, design trades, and down-select decisions for all mechanical subsystems from water purification through post-production H₂ purification
• Own 3D CAD design of complex parts and assemblies using SolidWorks or equivalent — including sheet metal, plastics, insulation systems, sealing methods, connectors, and fasteners
• Review and develop process flow diagrams, P&IDs, and mechanical design documentation
• Perform first-principles hand calculations for sizing and performance of fluid, thermal, and structural systems
• Collaborate closely with electrical and electronics engineering teams to integrate HV power electronics and LV control, sensing, and communications systems into mechanical enclosures
• Design packaging solutions for HV electrical assemblies — including bus bars, power modules, and high-current connectors — ensuring proper insulation, creepage/clearance compliance, and thermal management
• Design and validate cooling technologies (heat exchangers, forced-air systems) for thermal management of electrolyzer stacks, power electronics, and ancillary electrical components
• Ensure enclosure designs meet relevant electrical safety standards (UL, IEC, NFPA) for HV systems
• Define and manage interface control documents (ICDs) between mechanical and electrical subsystems
• Partner actively with manufacturing engineering to embed DFM and DFA principles from the earliest concept phase through production release
• Create and maintain full Balance-of-Plant (BoP) documentation including Bills of Materials, P&IDs, and fluid system specifications
• Hands-on experience or strong familiarity with gas (hydrogen, nitrogen, oxygen) and water piping systems, including pressure ratings, material compatibility, and leak testing protocols
• Develop test plans and lead laboratory test and validation activities to confirm product reliability, safety, and performance
• Create and maintain PLM documentation including Bills of Materials, engineering drawings, design calculations, and FMEAs

Requirements

• B.S. in Mechanical Engineering or equivalent; 6+ years of relevant experience in commercial product design and development
• First-principles understanding of statics, mechanics, materials science, heat transfer, thermodynamics, and fluid dynamics
• Extensive experience taking mechanical designs from concept through production, including prototype builds and manufacturing release
• Proven experience in DFM/DFA — working hand-in-hand with manufacturing partners
• Demonstrated experience packaging and integrating electromechanical systems involving both HV and LV electrical components
• Proficiency in 3D CAD (SolidWorks strongly preferred) and Thermal & Structural FEA tools
• Strong hands-on aptitude — comfortable in the lab, on the shop floor, and at the test rig
• Experience creating GD&T-compliant 2D fabrication drawings (ASME Y14.5)

Nice-to-Haves

• Advanced degree (M.S. or Ph.D.) in Mechanical Engineering or closely related field
• Experience with PEM electrolysis, fuel cell systems, or related electrochemical systems
• Hands-on experience with hydrogen, oxygen, nitrogen, or other high-purity gas systems — including pressure management, material selection (316L SS, PTFE, PEEK), and leak testing
• Experience with water purification technologies (deionization, ultrafiltration, reverse osmosis) and post-production gas purification
• Multi-physics and CFD simulation experience (ANSYS Fluent, COMSOL, or similar)
• Familiarity with electrical safety standards relevant to HV systems: UL 508A, IEC 60204, NFPA 70E
• Experience with PLM systems for BOM and drawing management

Compensation & Benefits

• Fully paid Medical, Dental, and Vision coverage
• Competitive salary and equity compensation commensurate with experience
• 401k Retirement Plan
• Paid sick days and vacation
• In-office lunches