Senior Mechanical Engineer

We are looking for a highly skilled Senior Mechanical Design Engineer to join our Core Technology team focused on high-temperature, high voltage energy storage systems. This role involves leading the design and development of ceramic, refractory, and insulation assemblies, as well as mechanical and electrical interfaces critical to thermal systems. The ideal candidate combines deep technical expertise with hands-on experience bringing complex mechanical designs from concept to production.   

  

What You’ll Do (responsibilities include but are not limited to):  

• Lead the mechanical design of components, assemblies, and systems operating at temperatures up to 1500 °C 

• Solve complex multiphysics design challenges involving heat transfer, fluid flow, and structural behavior in extreme environments. 

• Design and validate high-voltage heating elements and electrical interfaces (e.g., busbars, bolted joints), accounting for thermal, electrical, and mechanical to ensure reliability, safety, and compliance 

• Design for high-energy fault conditions, including arc flash risk, through appropriate geometry, insulation coordination and clearances 

• Design and validate insulation systems, including ceramic and refractory components, for thermal performance, durability, and manufacturability 

• Perform thermal, mass flow and mechanical analysis to identify key design drivers and validate performance 

• Define subsystem requirements and develop verification and validation strategies aligned with system-level performance goals 

• Lead and contribute to FMEA activities, drive risk identification, mitigation, and design robustness 

• Develop and support the execution of test strategies, including design of experiments (DOE) and specialized test setups, to validate design performance, reliability, and safety 

• Support rapid prototyping and iterative development across ceramics, refractories, metals 

• Lead design reviews, schedule planning, and cross-functional communication to drive program execution 

• Apply GD&T principles to ensure functional performance through tolerance analysis and robust design 

• Utilize CAD and PLM tools (SolidWorks preferred) for design, documentation, and configuration control 

• Generate clear technical documentation for internal teams, suppliers, and external stakeholders 

• Collaborate closely with manufacturing and supply chain to improve yield, establish process controls, and resolve root causes of failures 

 

What You'll Bring:  

•  Bachelor’s or Master’s degree in Mechanical Engineering or a related discipline. 

• 7+ years of engineering experience across multiple industries and technologies; energy systems experience preferred 

• Proven track record of taking designs from concept through high-volume production 

• Demonstrated expertise in high-temperature materials, thermal-mechanical systems, and high-voltage applications 

• Strong knowledge of relevant electrical and mechanical compliance standards (e.g., creepage and clearance, arc flash, ingress protection) 

• Familiarity with refractory manufacturing processes and high-temperature wire fabrication 

• Proficiency in FEA and 1D thermal analysis 

• Deep understanding of GD&T, tolerance stack-ups, and core mechanical design principles 

• Strong cross-functional collaboration and communication skills 

• Demonstrated commitment to engineering rigor, quality documentation, and schedule execution 

• Track record of driving cost reduction through design optimization 

 

Bonus Points!  

• Experience in a con