Senior Mechanical & Design Engineer
About The Position
Oxylus Energy is a climate-tech company developing electrochemical technology that converts carbon dioxide into carbon-neutral fuels and chemicals. The Senior Mechanical & Design Engineer will own the mechanical design of the CO₂ electrolyzer, from single cells to multi-cell stacks, and the mechanical aspects of the balance of stack. The role translates electrochemical requirements into robust, manufacturable hardware, including flow fields, bipolar plates, end plates, manifolds, seals, compression systems, current collectors, and fluid connections. This is a hands-on position involving modeling, drawings, building and testing designed hardware, and close collaboration with R&D and engineering teams to diagnose issues and improve performance, durability, and scalability. At the senior level, the engineer will set technical direction for stack architecture and scale-up, lead design reviews, and mentor other engineers. The role is on-site in Branford, Connecticut; the 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.
- Relevant experience by degree: B.S. with 7+ years, M.S. with 5+ years, or Ph.D. with 2+ years.
- Proficiency in 3D CAD such as SolidWorks, Creo, or NX, and in producing manufacturing drawings with GD&T.
- Familiarity with pressure equipment codes and standards such as ASME.
- 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.
- Sound understanding of sealing, compression, and fluid-containing vessels.
- Attention to detail and strong problem-solving and organizational skills.
- Good written, verbal, and presentation skills.
- Willingness to relocate to the Bridgeport/Stamford area within one year of the start date.
Nice To Haves
- Direct experience designing electrolyzer or fuel cell stacks.
- Experience with structural or thermal finite element analysis (FEA).
- 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 the 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 flow-field and manifold designs.
- 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.
- Build and assemble prototype cells and stacks, run 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 for hardware that handles pressurized and hazardous gases, including CO.
- Set technical direction for stack architecture and scale-up, lead design reviews, and mentor other engineers.
Benefits
- Medical, dental, and vision coverage.
- Paid sick days and vacation.
- 401(k) match.
- A diverse and inclusive work environment.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
