Sr. Staff Engineer, Manufacturing

At Bloom Energy, our vision for a world powered by clean, reliable, and affordable energy is more than just a dream—we’re making it reality.

For over two decades, we’ve been at the forefront of the global energy transition, pioneering solutions that empower critical industries to thrive in a rapidly digitizing, energy-intensive world. From revolutionizing power for AI-driven data centers to ensuring resilience for hospitals, electric grids, manufacturing facilities, and utilities, our solid oxide fuel cell (SOFC) and solid oxide electrolyzer (SOEC) technologies are redefining what’s possible by delivering energy abundance for all. With more than 30,000 fuel cell modules deployed worldwide, we are the trusted partner for Fortune 100 companies and innovators alike. Our cutting-edge solutions enable unparalleled “time-to-power” capabilities, reliability, and sustainability, ensuring our customers remain ahead in a world where soaring energy demand and intensifying energy scarcity are rapidly becoming the new norm.

At Bloom, we thrive on collaboration, bold thinking, and relentless innovation. We believe that, together, we can create a brighter, more sustainable future while tackling the most pressing challenges of the 21st century.

We are looking for a Sr. Staff Engineer, Manufacturing - Design for Manufacturability to join our team in one of today’s most exciting technologies. This role will report to Senior Manager, Manufacturing Engineering and based in Newark, DE.  This is a fully on-site, in office role.

Role and Responsibilities:

• Lead cross-functional Design for Manufacturability (DFM) and Design for Assembly (DFA) initiatives to ensure current and future product designs are optimized for manufacturability, cost-efficiency, and scalability from concept through production.
• Identify and challenge design constraints by collaborating with Product Design, and Quality teams to influence early-stage design decisions.
• Drive design simplification by recommending alternative materials, processes, and assembly techniques that reduce part count, improve yield, and lower cost.
• Establish and institutionalize DFM best practices, tools, and review processes across engineering and product development teams.
• Use data-driven approaches (e.g., DOE, SPC, FMEA) to quantify the impact of design changes on manufacturing KPIs.
• Play a pivotal role in translating optimized designs into scalable, high yield manufacturing processes, including process flow design, tooling requirements, and automation strategies.
• Align R&D, Manufacturing Engineering, and Operations teams around a unified manufacturing strategy that supports product performance, quality, and business objectives.
• Play a key role in the industrialization of mature Bloom Energy process nodes, enabling their integration into a scalable, highly automated, and Industry 4.0-compliant manufacturing ecosystem.

Skills and Experience: 

• Bachelor’s degree in mechanical engineering, Mechatronics, or a related field required; Master’s degree preferred.
• Over 6 years of experience in a high-volume manufacturing environment, with a strong focus on DFM/DFA implementation leading to scalable, cost-effective solutions.
• Strong proficiency in 3D CAD platforms (SolidWorks preferred).
• Extensive experience in mechanical product development with a focus on welded and formed structures, including Unishell enclosures designed for high-temperature fuel cell applications.
• Advanced knowledge of high-temperature and corrosion-resistant alloys, including Inconel, stainless steel, and Hastelloy, with hands-on experience in forming, joining, and post-processing techniques.
• Expertise with design and development of thermal insulation systems, including ceramic fiber blankets, aerogels, vacuum-insulated panels, thermal barrier coatings, expansion joint design, and high-temperature sealing technologies.
• Skilled in advanced welding processes including Gas Tungsten Arc Welding (GTAW), Gas Metal Arc Welding (GMAW), and automated orbital welding for high-integrity joints.

Physical Requirements (optional):

• Must be able to wear required Personal Protective Equipment (PPE) in designated areas.

Bloom Energy is an equal opportunity employer and makes employment decisions on the basis of merit. We are committed to compliance with all applicable laws providing equal employment opportunities. All qualified applicants will receive consideration for employment without regard to race, sex, color, religion, national origin, protected veteran status, or based on disability. Bloom Energy makes reasonable accommodation, consistent with applicable laws, for the known physical or mental limitations of an otherwise qualified applicant or e