Mechanical Design Engineer (Electrochemical Systems)

About RenewCO2

RenewCO2 is pioneering the next generation of electrochemical CO2 conversion technologies to produce sustainable aviation fuels and chemicals with unprecedented energy efficiency and cost-effectiveness. Our technology transforms industrial CO2 emissions into valuable products creating a circular carbon economy and driving the transition to a fossil-free future. Were building technology that creates economically viable pathways to decarbonization.

Position Overview

Were seeking a dynamic CO2 Electrolysis Stack Mechanical Engineer to join our engineering team during this pivotal phase of scaling from R&D to commercial deployment. You will lead the mechanical design optimization and testing of our next-generation CO2 electrolysis stacks working at the intersection of electrochemistry materials science and mechanical engineering to deliver high-performance manufacturable systems.

Key Responsibilities

Design & Development

• Lead mechanical design engineering for CO2 electrolysis stack systems including bipolar plates manifolds sealing systems and compression assemblies
• Create detailed 3D models and technical drawings using CAD software
• Develop and optimize stack assembly procedures and manufacturing processes
• Design pressurized gas systems including valves piping and pressure vessels in compliance with ASME BPVC and relevant industry standards

Analysis & Optimization

• Conduct computational fluid dynamics (CFD) modeling to optimize flow distribution and thermal management within stack assemblies
• Perform structural finite element analysis (FEA) to ensure mechanical integrity under operational conditions
• Execute tolerance analysis and develop Design for Manufacturing and Assembly (DFMA) strategies
• Conduct Design Failure Mode and Effects Analysis (DFMEA) for stack components

Testing & Validation

• Lead build and testing of prototype stack systems from initial concept through validation
• Develop comprehensive test protocols and Design Verification Plans & Reports (DVP&R)
• Collaborate with process engineers to integrate instrumentation and control systems
• Analyze performance data and implement design improvements based on test results

Documentation & Quality

• Maintain detailed engineering documentation including specifications BOMs and requirements traceability
• Develop and maintain quality control procedures and inspection protocols
• Create and conduct design reviews
• Support technology transfer activities for manufacturing scale-up

Required Qualifications

Education & Experience

• Bachelors degree in Mechanical Engineering Chemical Engineering or related field (Masters preferred)
• 5 years of experience in mechanical design engineering preferably in electrochemical systems pressurized gas systems or related technologies

Technical Skills

• Proficiency in CAD software (SolidWorks AutoCAD or similar)
• Strong experience with CFD analysis (ANSYS Fluent COMSOL or similar)
• Solid background in structural FEA and mechanics of materials
• Experience with tolerance analysis and statistical design methods
• Familiarity with manufacturing processes including machining photo etching welding and assembly

Core Competencies

• Deep understanding of fluid dynamics heat transfer and mass transport phenomena
• Experience with sealing and gasket design for high-performance applications
• Strong analytical and problem-solving capabilities
• Excellent project management and organizational skills
• Outstanding written and verbal communication abilities

Preferred Qualifications

• Experience with electrolysis systems (PEM alkaline or CO2 electrolysis)
• Experience with full product development lifecycle from concept through manufacturing
• Knowledge of electrochemical processes and cell stack design

What We Offer

Competitive Package

• Competitive salary commensurate with experience
• Equity participation
• Health dental and vision insurance
• Flexible PTO and parental leave policies

Professional Growth

• Collaborative environment with world-class scientists and engineers
• Professional development and conference attendance support

Work Environment

• State-of-the-art R&D facilities and equipment
• Inclusive mission-driven company culture
• Direct impact on developing transformative climate solutions

Join Our Mission

This is an exceptional opportunity to play a fundamental role in scaling breakthrough CO2 conversion technology that will help decarbonize aviation and chemical manufacturing. Youll work alongside a passionate team of innovators who are committed to creating real solutions for climate change while building a sustainable business.

If youre excited about applying your mechanical engineering expertise to solve one of the most important challenges of our time wed love to hear from you.

RenewCO2 is committed to building a diverse and inclusive team. We welcome applications from all qualified candidates regardless of race gender age religion sexual orientation or disability status.