Senior Mechanical Engineer
Rondo EnergyAlameda, California
Full Time
Posted March 24, 2026
$150k - $180k
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Job Description
A Senior Mechanical Design Engineer responsible for leading the design and development of high-temperature, high-voltage energy storage systems, including ceramic and refractory components, thermal and electrical interfaces, and ensuring system reliability, safety, and manufacturability through advanced analysis, testing, and cross-functional collaboration.
Key Responsibilities
- Lead the mechanical design of components, assemblies, and systems operating at high temperatures up to 1500°C
- Solve complex multiphysics design challenges involving heat transfer, fluid flow, and structural behavior in extreme environments
- Design and validate high-voltage heating elements and electrical interfaces for reliability and safety
- Design insulation systems, including ceramic and refractory components, for thermal performance and durability
- Perform thermal, mass flow, and mechanical analysis to validate performance and identify key design drivers
- Define subsystem requirements and develop verification and validation strategies
- Lead and contribute to FMEA activities, risk mitigation, and design robustness
- Support testing strategies, including design of experiments and specialized test setups
- Support rapid prototyping and iterative development of ceramic, refractory, and metal components
- Lead design reviews, schedule planning, and cross-functional communication to ensure project execution
- Apply GD&T principles to ensure functional performance through tolerance analysis and robust design
- Collaborate with manufacturing and supply chain to improve yield, establish process controls, and resolve failures
Requirements
- Bachelor's or Master's degree in Mechanical Engineering or a related discipline.
- 7 years of engineering experience across multiple industries and technologies.
- Experience in energy systems is preferred.
- Proven track record of taking designs from concept through high-volume production.
- Demonstrated expertise in high-temperature materials, thermal-mechanical systems, and high-voltage applications.
- Strong knowledge of relevant electrical and mechanical compliance standards, e.g., creepage and clearance, arc flash, ingress protection.
- Familiarity with refractory manufacturing processes and high-temperature wire fabrication.
- Proficiency in Finite Element Analysis (FEA) and 1D thermal analysis.
- Deep understanding of GD&T (Geometric Dimensioning and Tolerancing), tolerance stack-ups, and core mechanical design principles.
- Strong cross-functional collaboration and communication skills.
- Demonstrated commitment to engineering rigor, quality documentation, and schedule execution.
- Track record of driving cost reduction through design optimization.
- Ability to lead the mechanical design of components, assemblies, and systems operating at temperatures up to 1500°C.
- Ability to solve complex multiphysics design challenges involving heat transfer, fluid flow, and structural behavior in extreme environments.
- Ability to design and validate high-voltage heating elements and electrical interfaces, e.g., busbars, bolted joints, accounting for thermal, electrical, and mechanical considerations to ensure reliability, safety, and compliance.
- Ability to design for high-energy fault conditions, including arc flash risk, through appropriate geometry, insulation coordination, and clearances.
- Ability to design and validate insulation systems, including ceramic and refractory components, for thermal performance, durability, and manufacturability.
- Ability to perform thermal, mass flow, and mechanical analysis to identify key design drivers and validate performance.
- Ability to define subsystem requirements and develop verification and validation strategies aligned with system-level performance goals.
- Experience in leading and contributing to FMEA activities, driving risk identification, mitigation, and design robustness.
- Experience in supporting the execution of test strategies, including design of experiments (DOE) and specialized test setups, to validate design performance, reliability, and safety.
- Support for rapid prototyping and iterative development across ceramics, refractories, and metals.
- Experience in leading design reviews, schedule planning, and cross-functional communication to drive program execution.
- Application of GD&T principles to ensure functional performance through tolerance analysis and robust design.
- Proficiency with CAD and PLM tools, preferably SolidWorks, for design, documentation, and configuration control.
- Ability to generate clear technical documentation for internal teams, suppliers, and external stakeholders.
- Experience collaborating closely with manufacturing and supply chain to improve yield, establish process controls, and resolve root causes of failures.
Benefits & Perks
Annual salary range of $150,000 to $180,000
Comprehensive Medical Benefits
Dental Benefits
Vision Benefits
Life Insurance and ADD
Up to 13 paid holidays per year plus a company week-long holiday in December
Flexible time off policy
Catered lunches on-site
401(k) plan with company match
Equity compensation
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