Senior Mechanical Engineer – Thermal & Air Systems

Rondo Energy • Alameda, CA

7d • $170,000 - $200,000 • Hybrid

About The Position

We are looking for a hands-on Senior Mechanical Engineer to join our Core Technology team, focused on the design and development of hot air handling systems for high-temperature energy storage applications. This role is central to delivering robust ducting networks, plenum assemblies, dampers, louvers, and associated air-distribution equipment that operate reliably at elevated temperatures. The ideal candidate combines analytical depth with design and assembly knowledge, and a passion for solving complex thermal-fluid engineering challenges.

Requirements

• Bachelor's or Master's degree in Mechanical Engineering or a related discipline.
• 7+ years of engineering experience with a focus on air systems, industrial gas handling, or high-temperature process systems; energy industry experience preferred.
• Proven track record of taking designs from concept through fabrication and commissioning for one or multiple of following systems: Dampers, actuators, louvers, ducts, plenum, furnace
• Experience with high temperature equipment design. Experience with high-temperature materials: stainless steels, Inconel, refractory linings, ceramic fiber insulation, and high-temperature expansion joint materials.
• Knowledge of relevant codes and standards (e.g., API, ASME, NFPA, applicable EN standards for industrial ducting and pressure equipment).
• Strong cross-functional collaboration and communication skills; ability to work effectively with construction, commissioning, and operations teams.
• Demonstrated commitment to engineering rigor, quality documentation, and schedule execution.
• Track record of driving cost reduction through design optimization and standardization.
• Experience mentoring and developing junior engineers with authenticity and care.

Nice To Haves

• Experience working in an industrial construction environment (site supervision, field engineering).
• Ability to perform CFD analysis on duct networks, plenums, and damper assemblies.
• Familiarity with refractory-lined or high temperature ceramic fiber ductwork design and installation practices.
• Experience integrating high-temperature blower or fan systems with duct networks.
• Background in damper-actuator design, heat recovery systems, waste heat utilization, thermal-mechanical systems or thermal energy storage applications.

Responsibilities

• Lead the mechanical design of hot air ducting systems, plenum assemblies, and air distribution components operating at temperatures up to 1000 °C.
• Design, specify, and validate dampers (isolation, control, backdraft, and diverter types) and louvers for high-temperature service, including actuator selection and leakage performance requirements.
• Design plenum assemblies, transition pieces, expansion joints, and support structures that accommodate thermal growth while maintaining structural integrity.
• Define subsystem requirements and develop verification and validation (V&V) plans aligned with system-level performance, safety, and operational goals.
• Prepare technical documentation—drawings, specifications, and engineering calculations—for internal teams, fabricators, and external stakeholders.
• Perform thermal and fluid analyses to identify key design drivers; use FEA where required to confirm mechanical performance under thermal and pressure loads.
• Lead and contribute to FMEA activities to identify and mitigate risk; develop and execute test strategies, including design of experiments (DOE), to validate system performance and reliability.
• Support prototyping, test plans, vendor qualification, and iterative development across high-temperature metallic and insulated duct assemblies.
• Lead the air circulation sub-system for product development of Rondo’s current and next generation product line. Follow Rondo product development phase gate process, lead Rondo product development reviews and maintainphase gate documentation.
• Develop top level system architecture for Rondo Heat Battery Air Management and Heat Delivery systems.
• Lead and participate in design reviews, schedule planning, and cross-functional progress reporting to drive program execution.
• Utilize CAD and PLM tools (SolidWorks preferred) for design, documentation, and configuration control of air-system components.
• Collaborate with manufacturing, construction, and supply chain teams to improve quality, establish process controls, and resolve root causes of field failures.
• Develop duct sizing, routing, and layout using first-principles pressure drop calculations and 1D flow network analysis, ensuring compliance with velocity, pressure, and thermal expansion requirements.
• Solve coupled multiphysics problems involving heat transfer (conduction, convection, radiation), fluid flow, and structural behavior in high-temperature air systems.

Benefits

• Comprehensive Medical Benefits
• Dental & Vision Benefits
• Life Insurance and ADD
• Up to 13 paid holidays per year, in addition to a company week-long holiday in December
• Flexible time off policy
• Catered lunches on-site
• 401(k) plan with company match
• Equity compensation

What This Job Offers

• Job Type: Full-time
• Career Level: Senior