Senior Mechanical Design Engineer

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Compensation: 120000 USD – 150000 USD / Year

***We are unable to work with 3rd-party or corp-to-corp candidates for this position***

Overview:
Our client will be hiring a Senior Mechanical Design Engineer with a strong background in mechanical design, thermodynamics, fluid flow and structural analysis. The role will focus on R&D of advanced battery power module technology to ensure performance, reliability and cost. The deliverables will require significant input into the mechanical design: structural and fluidic analysis, testing and validation, prototyping, specification creation and implementation, quality support, etc. The ideal candidate will have a passion for sustainability and the environment, will thrive in a fast-paced entrepreneurial setting, be self-motivated, and have an interest in disruptive, cutting-edge technology.

This position is 100% onsite in Wilsonville, Oregon.

Responsibilities:

• Senior contributor to the mechanical design of stack and subsystem hardware (manifolds, flow fields, plates, frames, enclosures, seals) using 3D CAD and rigorous design control (models, drawings, specs, BOMs; GD&T).
• Analyze and optimize thermal/fluid performance and structural integrity (pressure/temperature/vibration/thermal cycling) using FEA/CFD. Translate insights into robust design updates.
• Engineer for manufacturability and reliability (DFM/DFA/DFR) across casting, machining, plastics (injection molding, extrusion, plastics welding), and sealing processes (welding, adhesives, gaskets).
• Select materials compatible with electrolytes and corrosive environments; address creep, fatigue, and stress-relaxation mechanisms with appropriate safety margins and life predictions.
• Correlate models to test: develop validation plans, define test articles/fixtures, analyze data, close the loop to simulation, and drive root-cause and corrective actions.
• Collaborate across all engineering and supply chain teams to convert performance targets into durable, cost-effective designs ready for production.
• Continuously improve cost, reliability, and serviceability while maintaining safety, compliance, and quality standards.

Qualifications:

• B.S. in Mechanical Engineering
• 5 years of experience in mechanical design and analysis of complex fluid or electrochemical systems
• Proficiency in 3D CAD (Inventor, SolidWorks, or equivalent) for parametric design, detailed drawings, and BOMs.
• Strong foundation in thermodynamics, fluid mechanics, and solid mechanics, with hands-on FEA/CFD and tolerance stack-ups.
• Developed detailed engineering drawings using GD&T principles per ASME Y14.5, incorporating a strong understanding of quality inspection methods to accurately define and verify critical-to-function (CTF) and critical-to-quality (CTQ) features.

Preferred:

• M.S. in Mechanical, Materials Science, Energy Systems, or Chemical Engineering.
• Experience designing for corrosive or reactive fluids and hermetic sealing (welds, adhesives, gaskets).
• Track record of cross-functional execution from concept to validated hardware (proto → pilot → production).
• Clear, concise communicator; self-directed; able to juggle multiple design workstreams.
• Ability to lift 50 lbs. unassisted
• Experience in battery, fuel cell, or power-generation system design.
• Demonstrated multiphysics experience (ANSYS, COMSOL, or equivalent) and test correlation.
• Scaling from prototype to production; cost and reliability ownership.
• Knowledge of electrolyte-compatible materials and corrosion mitigation.
• Experience with pressure-bound assemblies and pressure vessel considerations.
• Plastics and polymer component design for injection molding, extrusion, and plastics welding.
• Hands-on experience with CNC/CAM and other fabrication and machining techniques, with a solid understanding of tolerances, tool paths, and manufacturability trade-offs.
• Practical understanding of material creep, fatigue, and stress relaxation, including creep and fatigue failure analysis and life prediction for polymers and metals under sustained loads, vibration, and thermal cycling.
• Programming proficiency using engineering platforms such as Python or MATLAB for design automation, data analysis, or simulation post-processing.

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