Mechanical Design Engineer (Electrochemical Systems)

R

RenewCO₂

Mechanical Design Engineer (Electrochemical Systems)

Somerset, NJ
Full Time
Paid
  • Responsibilities

    About RenewCO 2

    RenewCO2 is pioneering the next generation of electrochemical CO2 conversion technologies to produce sustainable aviation fuels and chemicals with unprecedented energy efficiency and cost-effectiveness. Our technology transforms industrial CO2 emissions into valuable products, creating a circular carbon economy and driving the transition to a fossil-free future. We're building technology that creates economically viable pathways to decarbonization.

    Position Overview

    We're seeking a dynamic CO2 Electrolysis Stack Mechanical Engineer to join our engineering team during this pivotal phase of scaling from R&D to commercial deployment. You will lead the mechanical design, optimization, and testing of our next-generation CO2 electrolysis stacks, working at the intersection of electrochemistry, materials science, and mechanical engineering to deliver high-performance, manufacturable systems.

    Key Responsibilities

    Design & Development

    • Lead mechanical design engineering for CO2 electrolysis stack systems, including bipolar plates, manifolds, sealing systems, and compression assemblies
    • Create detailed 3D models and technical drawings using CAD software
    • Develop and optimize stack assembly procedures and manufacturing processes
    • Design pressurized gas systems including valves, piping, and pressure vessels in compliance with ASME BPVC and relevant industry standards

    Analysis & Optimization

    • Conduct computational fluid dynamics (CFD) modeling to optimize flow distribution and thermal management within stack assemblies
    • Perform structural finite element analysis (FEA) to ensure mechanical integrity under operational conditions
    • Execute tolerance analysis and develop Design for Manufacturing and Assembly (DFMA) strategies
    • Conduct Design Failure Mode and Effects Analysis (DFMEA) for stack components

    Testing & Validation

    • Lead build and testing of prototype stack systems from initial concept through validation
    • Develop comprehensive test protocols and Design Verification Plans & Reports (DVP&R)
    • Collaborate with process engineers to integrate instrumentation and control systems
    • Analyze performance data and implement design improvements based on test results

    Documentation & Quality

    • Maintain detailed engineering documentation including specifications, BOMs, and requirements traceability
    • Develop and maintain quality control procedures and inspection protocols
    • Create and conduct design reviews
    • Support technology transfer activities for manufacturing scale-up

    Required Qualifications

    Education & Experience

    • Bachelor's degree in Mechanical Engineering, Chemical Engineering, or related field (Master's preferred)
    • 5+ years of experience in mechanical design engineering, preferably in electrochemical systems, pressurized gas systems, or related technologies

    Technical Skills

    • Proficiency in CAD software (SolidWorks, AutoCAD, or similar)
    • Strong experience with CFD analysis (ANSYS Fluent, COMSOL, or similar)
    • Solid background in structural FEA and mechanics of materials
    • Experience with tolerance analysis and statistical design methods
    • Familiarity with manufacturing processes including machining, photo etching, welding, and assembly

    Core Competencies

    • Deep understanding of fluid dynamics, heat transfer, and mass transport phenomena
    • Experience with sealing and gasket design for high-performance applications
    • Strong analytical and problem-solving capabilities
    • Excellent project management and organizational skills
    • Outstanding written and verbal communication abilities

    Preferred Qualifications

    • Experience with electrolysis systems (PEM, alkaline, or CO2 electrolysis)
    • Experience with full product development lifecycle from concept through manufacturing
    • Knowledge of electrochemical processes and cell stack design

    What We Offer

    Competitive Package

    • Competitive salary commensurate with experience
    • Equity participation
    • Health, dental, and vision insurance
    • Flexible PTO and parental leave policies

    Professional Growth

    • Collaborative environment with world-class scientists and engineers
    • Professional development and conference attendance support

    Work Environment

    • State-of-the-art R&D facilities and equipment
    • Inclusive, mission-driven company culture
    • Direct impact on developing transformative climate solutions

    Join Our Mission

    This is an exceptional opportunity to play a fundamental role in scaling breakthrough CO2 conversion technology that will help decarbonize aviation and chemical manufacturing. You'll work alongside a passionate team of innovators who are committed to creating real solutions for climate change while building a sustainable business.

    If you're excited about applying your mechanical engineering expertise to solve one of the most important challenges of our time, we'd love to hear from you.

    RenewCO 2 is committed to building a diverse and inclusive team. We welcome applications from all qualified candidates regardless of race, gender, age, religion, sexual orientation, or disability status.