Sr. Development Engineer
Air CompanyNew Britain, Pennsylvania
Full Time
Posted February 3, 2026
Hydrogen & Fuel Cells
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Job Description
A Senior Development Engineer responsible for pilot-scale testing, process development, and modeling to support the commercialization of sustainable aviation fuels using AIRCO's innovative carbon conversion technology.
Key Responsibilities
- Design, plan, and execute pilot-unit and bench-scale testing programs for SAF process development and scale-up
- Operate, troubleshoot, and optimize reaction and separation systems
- Develop experimental strategies to address data gaps for commercialization readiness
- Analyze large experimental datasets and develop mechanistic models of reactions and separations
- Utilize analytical equipment to interpret data and ensure data quality and reproducibility
- Translate experimental results into inputs for engineering design and support technology readiness progression
- Collaborate with cross-functional teams to support development, demonstration, and early commercial deployment of SAF technology
- Apply creative problem-solving to address technical challenges and identify process improvements
Requirements
- M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a closely related discipline
- Significant experience in hands-on experimental development, pilot-scale testing, or process development
- Strong grounding in thermodynamics, reaction engineering, and separation fundamentals
- Demonstrated ability to analyze large datasets and extract mechanistic insight, not just empirical fits
- Experience with numerical tools, simulation software, or data analysis platforms such as Aspen, MATLAB, Python, or similar
- Proven troubleshooting skills in experimental or pilot-plant environments
- Experience in fuels, petrochemicals, refining, catalysis, or sustainable energy technologies
- Familiarity with scale-up challenges, process modeling, and commercialization workflows
- Ability to operate, troubleshoot, and optimize reaction and separation systems
- Ability to design, plan, and execute pilot-unit and bench-scale testing programs to support SAF process development and scale-up
- Ability to develop experimental strategies to close data gaps critical for commercialization readiness
- Ability to utilize and interpret data from analytical equipment such as GC, HPLC, spectroscopy, physical property measurements
- Ensure data quality, reproducibility, and traceability to support design decisions and scale-up
- Support translation of experimental results into actionable inputs for Engineering Design Information (EDI) delivery
- Support technology readiness progression from development through demonstration and early commercial deployment
- Apply a creative, hypothesis-driven approach to solving complex technical challenges
- Identify opportunities for process improvement, risk reduction, and performance optimization
- Contribute to intellectual property development, technical documentation, and knowledge transfer
- Access to technology, software, and information subject to governmental access control restrictions, with the ability to obtain and maintain appropriate government authorization such as security clearance or export license
Benefits & Perks
Full coverage for employee health, dental, and vision insurance premiums starting Day 1
70% coverage for spouse and dependent health, dental, and vision insurance premiums
Health Savings Account (HSA) and Flexible Spending Account (FSA) options
Company-paid Short-Term Disability insurance
Optional Long-Term Disability and Life Insurance plans
Flexible and generous paid time off, including national holidays, sick leave, and paid family leave
Tax-deferred 401(k) plan with a 3% company match
Pre-tax commuter benefits for transit and parking with monthly company contributions
Ancillary benefits such as pet insurance and financial wellness programs
Employee wellness program including Wellhub and One Medical
Company-sponsored events and weekly catered lunches
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