Staff Mechanical Design Engineer
Rondo EnergyAlameda, California
Full Time
Posted October 24, 2025
$180k - $225k
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Application opens on company website
Job Description
A highly skilled Mechanical Design Engineer responsible for leading the design and development of high-temperature, high-voltage energy storage system components, focusing on ceramic, refractory, and insulation assemblies, from concept to production, ensuring reliability, manufacturability, and compliance.
Key Responsibilities
- Lead the mechanical design of high-temperature components, assemblies, and systems
- Design and validate ceramic, refractory, and insulation parts and assemblies
- Develop heating elements and high-temperature electrical joints for reliability and manufacturability
- Perform heat and mass flow analyses, CFD simulations, and FEA to validate mechanical performance
- Contribute to and lead FMEA activities and apply GD T principles for tolerance analysis
- Develop component test methodologies and design of experiments (DOE)
- Create and manage CAD models, documentation, and configuration control using SolidWorks and PLM software
- Formulate subsystem requirements and prepare documentation for suppliers and stakeholders
- Collaborate with manufacturing and supply chain teams to improve yields and resolve failures
- Support rapid prototyping across various materials and lead design reviews and schedule estimation
Requirements
- Bachelor's or Master's degree in Mechanical Engineering or related discipline
- Proven experience taking designs from concept through to production at volume
- Demonstrated design experience with high-temperature materials, thermal-mechanical systems, and high voltage systems
- Knowledge of electrical and mechanical compliance standards such as creepage and clearance, arc flash protection, and ingress protection
- Familiarity with refractory manufacturing processes e.g., casting and high-temperature wire fabrication bending, straightening
- Proficiency in FEA, 1D thermal analysis, and CFD
- Expertise in GD T, tolerance stack-ups, and mechanical design fundamentals
- Strong communication and collaboration skills able to work cross-functionally and empower others
- Commitment to schedule adherence, quality documentation, and engineering rigor
- Track record of successful cost reduction initiatives and designs
- Ability to perform tolerance analysis, including thermal expansion effects
- Ability to formulate robust subsystem requirements and prepare documentation for outside suppliers and stakeholders
- Ability to develop component test methodologies and design of experiments (DOE)
- Experience with CAD and PLM software, with SolidWorks preferred for design, documentation, and configuration control
- Willingness to be on-site at Alameda Headquarters with up to 10% travel to project sites
Benefits & Perks
Annual salary range of $180,000 to $225,000
Eligible for Rondo's excellent benefits package
Additional compensation in the form of equity
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