Mechanical & Design Engineer II - III
About The Position
Oxylus Energy is hiring a Mechanical & Design Engineer at the Engineer II–III level to own the mechanical design of its CO₂ electrolyzer, from single cells to multi-cell stacks, and the mechanical components of the balance of stack. The role translates electrochemical requirements into robust, manufacturable hardware, including flow fields, bipolar and end plates, manifolds, seals, compression systems, current collectors, and fluid connections. This is a hands-on position that includes modeling and producing drawings as well as building and testing designed hardware. The engineer will work with R&D and engineering teams to diagnose issues and improve performance, durability, and scalability. The position is on-site in Branford, Connecticut. The successful candidate must be willing to relocate to the Bridgeport/Stamford area within one year of the start date.
Requirements
- Degree in Mechanical Engineering or a related field.
- For Engineer II: B.S. with 2–4 years or M.S. with 1–2 years of relevant experience.
- For Engineer III: B.S. with 4+ years, M.S. with 2–4 years, or Ph.D. with 0–2 years of relevant experience.
- Proficiency in 3D CAD such as SolidWorks, Creo, or NX, and in producing manufacturing drawings with GD&T.
- Hands-on experience with CFD tools such as ANSYS Fluent or COMSOL.
- Familiarity with electrochemical hardware development, such as electrolyzers, fuel cells, or batteries.
- Hands-on experience building and testing mechanical prototypes.
- Understanding of sealing, compression, and fluid-containing vessels.
- Attention to detail and strong problem-solving and organizational skills.
- Good written, verbal, and presentation skills.
Nice To Haves
- Direct experience designing electrolyzer or fuel cell stacks.
- Experience with structural or thermal finite element analysis (FEA).
- Familiarity with pressure equipment codes and standards, such as ASME.
- Experience with machining, 3D printing, or other rapid-prototyping methods.
- Experience with CAM software.
- Experience scaling hardware from lab prototypes to pilot or production designs.
Responsibilities
- Own mechanical design of CO₂ electrolyzer cells and stacks, including flow fields, bipolar plates, end plates, manifolds, gaskets and seals, and compression hardware.
- Design and specify mechanical balance-of-stack components, including fluid connections, current collectors, insulation, and mounting and integration hardware.
- Use computational fluid dynamics (CFD) to model gas and liquid flow, pressure drop, and heat transfer, and optimize designs based on results.
- Produce detailed CAD models and manufacturing drawings with appropriate tolerancing (GD&T), and manage design revisions and documentation.
- Select materials for chemical compatibility, corrosion resistance, and electrical and thermal performance in an electrochemical environment.
- Design and build prototype cells and stacks, perform leak and pressure checks, and support electrochemical testing on test stations.
- Diagnose hardware-related failures, including leaks, uneven compression, flow maldistribution, and corrosion, and implement design fixes.
- Work with machine shops and suppliers on fabrication, quotes, and quality, and design for manufacturability as hardware scales to larger formats.
- Contribute to safety reviews of hardware handling pressurized and hazardous gases, including CO.
- Occasionally perform hands-on manufacturing processes, including operating CNC machines or band saws.
Benefits
- Competitive salary.
- Medical coverage.
- Dental coverage.
- Vision coverage.
- Paid sick days and vacation.
- 401k match.
- A diverse and inclusive work environment.
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
