Senior Mechanical Engineer, Fuel Cells

The Senior Mechanical Engineer leads the design, development, and validation of complex mechanical systems for Solid Oxide Fuel Cell (SOFC) power systems used in uncrewed aerial systems and portable power generators. The role owns major subsystem designs, balancing performance, reliability, and manufacturability, and provides hands-on leadership during prototype builds, test campaigns, and production transitions. The engineer coordinates cross-functional design integration, participates in design reviews, and contributes to design standards and process improvements across multiple programs.

Responsibilities

• Lead the design, modeling, and analysis of major mechanical and structural subsystems for SOFC power systems and their supporting products.
• Perform and review tolerance analysis, structural analysis (FEA), and materials selection.
• Oversee design documentation, drawing release, and configuration management activities.
• Coordinate design integration across disciplines—mechanical, electrical, and software.
• Guide prototype builds, resolving issues related to manufacturability, fit, and performance.
• Develop and execute test plans to validate structural integrity and system performance.
• Analyze data, present results, and make informed decisions.
• Lead and participate in design reviews (CoDR, PDR, CDR) and incorporate feedback into designs.
• Support production readiness and quality verification for new and existing products.
• Contribute to continuous improvement initiatives in design standards, configuration management, and documentation processes.

Requirements

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field required.
• 4–7 years of relevant experience in mechanical or aerospace engineering, with demonstrated ownership of major subsystems or assemblies.
• Experience with Fuel Cells, Power Generators, High Temperature systems, Fluid management systems, or DC Power Electronics
• Proven experience developing products for aerospace, defense, or similarly regulated environments.
• Experience supporting prototype, production, and test activities in a hands-on capacity.
• Advanced proficiency with CAD modeling and drafting (SolidWorks preferred).
• Deep understanding of GD&T, mechanical drawing standards, and documentation control.
• Working knowledge of materials, composites, machined parts, and structural integration.
• Experience applying engineering analyses, including FEA, to support design development and optimization.
• Familiarity with PDM/PLM systems (e.g., SolidWorks PDM, Windchill).
• Strong working knowledge of processes for prototyping and large-scale manufacturing.

Nice to have

• Copy of preferred qualifications Master’s degree in Mechanical or Aerospace Engineering.
• 6–8 years of experience designing mechanical systems for UAS, Aerospace or Defense applications.
• Experience leading subsystem integration efforts and participating in flight or environmental testing.
• Experience with advanced analysis tools (FEA, CFD, or fatigue analysis).
• Familiarity with composite layup design, bonded structures, or lightweight mechanisms.
• Experience developing and reviewing engineering standards or process documentation.
• Familiarity with systems engineering practices (DFMEA/PFMEA) and requirements traceability.
• Strong leadership presence with the ability to influence technical direction.
• Excellent communication and collaboration across multi-disciplinary teams.
• Analytical mindset with strong problem-solving and root-cause analysis capabilities.
• Organized and detail-oriented with experience managing multiple design tasks simultaneously.

Benefits

• Matching 401(k)
• Paid PTO
• Paid holidays
• Medical, vision, and dental insurance
• Group Short-Term & Long-Term Disability
• HSA and FSA Options
• Critical Care Plan
• Accident Care Plan
• Employee Stock Purchase Plan