Senior Design Engineer

Vulcan Elements•Research Triangle Park, NC

13d

About The Position

Vulcan Elements is seeking a Senior Design Engineer to own designs for parts and equipment in its R&D and pilot facility, from initial measurements and concepts through fabrication drawings, assembly, and as-built documentation. The role uses SolidWorks, Fusion 360, or similar CAD software to translate evolving process needs into practical, buildable parts and assemblies. The ideal candidate combines mechanical design skills with hands-on machining, building, welding, repair, or similar experience and works closely with engineers, technicians, and fabricators to make designs work in practice. The position supports design and development of components and equipment for high-temperature molten-salt electrochemical cells and powder-metal feed systems, as well as tooling, fixtures, and modifications for R&D and pilot projects. It also supports fabrication, equipment builds, drawings, spare parts, supplier quotations, and revision-controlled documentation. The responsibilities outlined are not exhaustive and may change according to business needs.

Requirements

Technical training in CAD, drafting, or mechanical design, or equivalent practical experience.
Demonstrated experience designing mechanical parts and assemblies in SolidWorks, Fusion 360, or similar parametric CAD software.
Hands-on experience in machining, fabrication, welding, equipment assembly, repair, or a similar trade.
Ability to produce clear shop drawings and apply appropriate dimensions, tolerances, and fits.
Ability to use measuring tools and translate physical parts and equipment into accurate CAD models.
Understanding of manufacturing constraints and how design choices affect cost, lead time, and buildability.
Ability to incorporate feedback from the shop floor and work through design changes in a fast-moving R&D environment.
Strong attention to detail, organized documentation, and clear communication with engineers, technicians, and suppliers.
Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Nice To Haves

Experience with high-temperature equipment, materials selection at high temperature, or metals processing equipment.
Experience with powder handling, press feed systems, tooling, or precision-machined components.
Experience with copper busbars or buspipes, cooled assemblies, weldments, or refractory components.
Familiarity with GD&T, tolerance stack-ups, CAD data management, or CAM workflows.
Experience supporting pilot plants, prototype builds, or equipment commissioning.

Responsibilities

Design reactor parts, refractory geometry, cathodes, lids, and replacement components for high-temperature molten-salt electrochemical cells.
Develop powder-metal feed-system parts, including hoppers, feed chutes, interfaces, and mechanisms.
Add features to machined components and design tooling, fixtures, and equipment modifications for R&D and pilot projects.
Create parametric 3D models and assemblies, checking fit, interference, clearances, and access for installation and maintenance.
Work with engineers to incorporate material compatibility, thermal expansion, electrical isolation, and cooling requirements into reviewed designs.
Design for available manufacturing methods and practical shop constraints, including machining access, achievable tolerances, standard stock sizes, inspection requirements, weld access, assembly sequence, fasteners, and serviceability.
Measure existing equipment and reverse-engineer worn or undocumented parts; verify critical dimensions before fabrication.
Work directly with machinists, welders, suppliers, and technicians to resolve build issues, check fit, and improve designs after testing.
Produce fabrication-ready drawings with dimensions, tolerances, materials, finishes, and applicable weld details.
Maintain bills of materials, part numbers, CAD files, and revision-controlled drawing packages.
Own spare-part drawings and update as-built records so replacement parts can be ordered and installed reliably.
Support supplier quotations and review proposed manufacturing changes with the responsible engineer.
Manage multiple design requests and communicate priorities, lead times, and design changes to the project team.