Sr. Development Engineer

About AIRCO
AIRCO is a world leader in carbon conversion technology paving the way to global energy security by transforming CO₂ into a valuable resource. Its proprietary AIRMADE Technology is an adaptable platform that allows any industry to efficiently produce high-demand fully-formulated synthetic fuels from waste CO₂ and hydrogen.

The company has commercial partnerships with airlines including JetBlue and Virgin Atlantic amongst others and has been awarded multiple government contracts including with NASA and the United States Department of Defenses Defense Innovation Unit. The company has received industry recognition through awards such as Time Best Inventions Inc. Best in Business Fast Company World Changing Ideas and the XPrize for Carbon Removal.

AIRCOs many accolades include winning the prestigious Green Chemistry Challenge Award from the Environmental Protection Agency in October 2023 an award given to organizations that reinvent processes to reduce the generation of hazardous substances and byproducts. AIRCO was also declared a winner for the World Economic Forum UpLink Sustainable Aviation Challenge which accelerates the development of promising technology pathways that enable widespread uptake of SAF.

The Position

We are seeking a Senior Development Engineer to play a critical role in commercializing AIRCOS Sustainable Aviation Fuels (SAF) technology.. This role is highly hands-on combining first-principles engineering with pilot-scale execution to generate the experimental data and mechanistic models required for scale-up and Engineering Design Information (EDI) delivery.

This individual will play a key role in the design and execution of concepting executing and evaluating experimental programs to enable robust yield and performance models supporting Engineering Design Information package (EDI) delivery. The position requires close integration of experimental work analytical characterization to build mechanistic understanding and develop solid numerical models of process reactions and separations. This role is based in New Britain PA.

What you get to do

Experimental & Pilot-Scale Development

• Design plan and execute pilot-unit and bench-scale testing programs to support SAF process development and scale-up
• Operate troubleshoot and optimize reaction and separation systems identifying root causes of performance deviations
• Develop experimental strategies to close data gaps critical for commercialization readiness

Data Analysis & Model Development

• Handle and interpret large complex experimental datasets identifying trends and correlations
• Develop mechanistic yield reaction and separation models grounded in thermodynamics and transport fundamentals
• Integrate experimental data with numerical statistical and simulation tools to improve model accuracy and predictability

Analytical & Characterization Work

• Utilize and interpret data from analytical equipment (e.g. GC HPLC spectroscopy physical property measurements)
• Ensure data quality reproducibility and traceability to support design decisions and scale-up

Commercialization & EDI Support

• Translate experimental results into actionable inputs for EDI/BEDP delivery
• Support technology readiness progression from development through demonstration and early commercial deployment
• Collaborate with cross-functional teams including R&D engineering operations and project management

Innovation & Problem Solving

• 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

What you bring to AIRCO

• 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 (e.g. Aspen MATLAB Python 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
• Experience supporting or delivering EDI / FEL engineering packages

Bonus Points

• Knowledge of SAF pathways and regulatory or sustainability considerations is a plus

Working at AIRCO - In addition to standard medical and dental benefits that kick in Day 1 we provide:

Comprehensive Health Benefits

• Full coverage for employee base premiums on health dental and vision insurance.
• 70% coverage for spouse and dependent base premiums.
• Choose between base plans or enhanced options to fit your needs.

Health Savings & Flexibility

• Access company-sponsored HSA and FSA accounts to save on healthcare and dependent care expenses.

Income Protection & Insurance

• Company-paid Short-Term Disability insurance.
• Optional Long-Term Disability and Life Insurance plans.

Time Off & Leave

• Flexible and generous paid time off including national holidays and sick leave.
• Paid family leave to support you during important life moments.

Retirement Savings

• Tax-deferred 401(k) plan with a 3% company match to help you invest in your future.

Commuter Benefits

• Pre-tax savings on transit and parking plus monthly company contributions.

Additional Perks

• Ancillary benefits through Sequoia including pet insurance and financial wellness programs.
• Employee wellness program to support your of Wellhub & One Medical.
• Company-sponsored events and programs that promote an inclusive and values-driven workplace.
• In person weekly catered lunch every Wednesday.

At AIRCO we value employees for their unique perspectives. We are an inclusive affirmative action Equal Employment Opportunity employer. We consider applicants without regard to actual or perceived race color creed religion national origin ancestry citizenship status age sex or gender (including pregnancy childbirth pregnancy-related conditions and lactation) gender identity or expression (including transgender status) sexual orientation marital status military service and veteran status present or past history of intellectual learning mental or physical disability (including but not limited to blindness) unless AIRCO determines that such disability prevents performance of the work involved genetic information or any other characteristic protected by applicable federal state or local laws and ordinances.

Dont meet every single requirement Studies have shown that women marginalized genders and people of color are less likely to apply to jobs unless they meet every single qualification. At AIRCO we are dedicated to building a diverse inclusive and authentic workplace so if youre excited about this role but your past experience doesnt align perfectly with every qualification in the job description we encourage you to apply anyways. You may be just the right candidate for this or other roles

This position requires access to technology software and other information that is subject to governmental access control restrictions due to export controls security classification and/or designation as Controlled Unclassified Information. Employment in this position is conditioned on the candidates ability to obtain and maintain appropriate government authorization to access technology or information to the extent required including without limitation a security clearance export license or other documentation required to establish authorization to receive access to such items technology or information.

We may delay commencement of employment rescind an offer of employment terminate employment and/or modify job responsibilities compensation benefits and/or access to Company facilities and information systems as we deem appropriate in order to ensure compliance with applicable government access control restrictions.

I consent to transfer my data to Air Company in the U.S. and to its use in accordance with the Air Company and I opt in to receiving information from Air Company. Air Company does not sell or share personal information to third parties within the meanings given under applicable laws.