Senior Mechanical Engineer – Thermal & Air Systems

We are looking for a hands-on Senior Mechanical Engineer to join our Core Technology team, focused on the design and development of hot air handling systems for high-temperature energy storage applications. This role is central to delivering robust ducting networks, plenum assemblies, dampers, louvers, and associated air-distribution equipment that operate reliably at elevated temperatures. The ideal candidate combines analytical depth with design and assembly knowledge, and a passion for solving complex thermal-fluid engineering challenges. 

 

What You’ll Do 

Responsibilities include but are not limited to: 

 

• Lead the mechanical design of hot air ducting systems, plenum assemblies, and air distribution components operating at temperatures up to 1000 °C. 

• Design, specify, and validate dampers (isolation, control, backdraft, and diverter types) and louvers for high-temperature service, including actuator selection and leakage performance requirements. 
• Design plenum assemblies, transition pieces, expansion joints, and support structures that accommodate thermal growth while maintaining structural integrity. 

• Define subsystem requirements and develop verification and validation (V&V) plans aligned with system-level performance, safety, and operational goals. 

• Prepare technical documentation—drawings, specifications, and engineering calculations—for internal teams, fabricators, and external stakeholders. 

• Perform thermal and fluid analyses to identify key design drivers; use FEA where required to confirm mechanical performance under thermal and pressure loads. 

• Lead and contribute to FMEA activities to identify and mitigate risk; develop and execute test strategies, including design of experiments (DOE), to validate system performance and reliability. 

• Support prototyping, test plans, vendor qualification, and iterative development across high-temperature metallic and insulated duct assemblies. 

• Lead the air circulation sub-system for product development of Rondo’s current and next generation product line. Follow Rondo product development phase gate process, lead Rondo product development reviews and maintainphase gate documentation.  

• Develop top level system architecture for Rondo Heat Battery Air Management and Heat Delivery systems.  

• Lead and participate in design reviews, schedule planning, and cross-functional progress reporting to drive program execution. 
• Utilize CAD and PLM tools (SolidWorks preferred) for design, documentation, and configuration control of air-system components. 
• Collaborate with manufacturing, construction, and supply chain teams to improve quality, establish process controls, and resolve root causes of field failures. 
• Develop duct sizing, routing, and layout using first-principles pressure drop calculations and 1D flow network analysis, ensuring compliance with velocity, pressure, and thermal expansion requirements. 
• Solve coupled multiphysics problems involving heat transfer (conduction, convection, radiation), fluid flow, and structural behavior in high-temperature air systems. 

 

What You’ll Bring 

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

• 7+ years of engineering experience with a focus on air systems, industrial gas handling, or high-temperature process systems; energy industry experience preferred. 

• Proven track record of taking designs from concept through fabrication and commissioning for one or multiple of following systems: Dampers, actuators, louvers, ducts, plenum, furnace 
• Experience with high temperature equipment design. Experience with high-temperature materials: stainless steels, Inconel, refractory linings, ceramic fiber insulation, and high-temperature expansion joint materials. 
• Knowledge of relevant codes and standards (e.g., API, ASME, NFPA, applicable EN standards for industrial ducting and pressure equipment). 

• Strong cross-functional collaboration a