Senior/Principal Mechanical Stack Engineer - Bipolar PlatesSenior/Principal Mechanical Stack Engineer - Bipolar PlatesGet AI-powered advice on this job and more exclusive features.This range is provided by Masverde. Your actual pay will be based on your skills and experience — talk with your recruiter to learn more.Base pay range$140,000.00/yr - $210,000.00/yrDirect message the job poster from MasverdeMy client is developing a novel electrolyzer technology which allows them to produce clean hydrogen reliably, efficiently, affordably, with a scale-able solution. They have recently completed a significant fundraise in a difficult investment market and are set to grow. With a number of functioning pilots they are now looking to scale their solution to meet the customer demand they are already seeing.As a Mechanical Engineer focused on electrolyzer stack design, you will drive the selection, development, and optimization of critical stack components. Partnering closely with the team, you will lead design iterations, prototyping, and scaling for production, playing a key role in advancing overall stack performance. This position demands strong technical expertise, hands-on problem solving, and a collaborative mindset in a fast-paced, dynamic environment.Key ResponsibilitiesLead the design, development, testing, and validation of essential stack components, including fluid distribution plates, cell frames, seals, and bipolar plates, ensuring alignment with performance targets.Apply knowledge of materials and coatings for electrolyzer stack components.Optimize fluid distribution and thermal management within the stack using thermodynamics, two-phase flow analysis, FEA, and CFD tools to enhance performance and durability.Conduct detailed compression and stack-up tolerance analyses to ensure effective sealing and mechanical integrity across varying operating conditions and service lifetimes.Collaborate with suppliers and internal teams to design components for manufacturability via injection molding, stamping, etching, CNC machining, and coating processes.Ensure designs meet scalability, cost, quality, and performance objectives.Lead root cause analyses and troubleshooting efforts for prototype and production stack issues, including field failures.Develop and execute testing protocols to validate component performance and identify areas for improvement.Design custom fixtures, jigs, and diagnostic tools to assess and refine flow distribution during design iterations.QualificationsBachelor’s degree (BS) required; Master’s (MS) or PhD preferred in Mechanical Engineering, Chemical Engineering, Materials Science, or a related discipline.Minimum of 5 years of relevant experience, ideally within PEM electrolyzers, fuel cells, or related technologies.Demonstrated success in taking complex mechanical components from concept through manufacturing and field troubleshooting.Expertise in tolerance analysis, design validation, and supplier engagement.Proficient in FEA, CFD, and fluid flow visualization techniques.Strong knowledge of high-precision manufacturing processes such as injection molding, stamping, etching, and coatings.Understanding of thermodynamics, fluid flow, and heat transfer within electrochemical systems.Seniority levelSeniority levelMid-Senior levelEmployment typeEmployment typeFull-timeJob functionJob functionEngineering, Manufacturing, and DesignIndustriesEnergy Technology and Services for Renewable EnergyReferrals increase your chances of interviewing at Masverde by 2xSign in to set job alerts for “Mechanical Engineer” roles.Mountain View, CA $94,050.00-$141,550.00 5 days agoSunnyvale, CA $139,000.00-$200,000.00 1 week agoSunnyvale, CA $170,000.00-$240,000.00 1 week agoPalo Alto, CA $168,000.00-$179,000.00 3 weeks agoFremont, CA $139,000.00-$200,000.00 4 days agoMountain View, CA $80,000.00-$102,000.00 3 days agoSunnyvale, CA $111,000.00-$164,000.00 1 week agoSan Jose, CA $115,200.00-$153,600.00 1 week agoSan Francisco, CA $135,000.00-$135,000.00 3 weeks agoSan Jose, CA $115,000.00-$135,000.00 1 week agoSunnyvale, CA $108,100.00-$182,900.00 2 weeks agoAlameda, CA $95,000.00-$134,000.00 1 week agoMechanical Engineer (Autonomous Vehicles)Palo Alto, CA $100,000.00-$150,000.00 3 weeks agoSan Jose, CA $120,000.00-$150,000.00 2 weeks agoSan Francisco, CA $140,000.00-$270,000.00 8 months agoWe’re unlocking community knowledge in a new way. Experts add insights directly into each article, started with the help of AI. #J-18808-Ljbffr