R&D Mechanical Design Engineer

Larsen & Toubro; Surat; On-site; INR 1,800,000 - 2,800,000; Full time

Job summary

Larsen & Toubro in Surat, India, seeks a Senior Mechanical Design Engineer to support alkaline electrolyser stack design for large-scale hydrogen production systems, focusing on multi-MW class stacks as a product platform.

You will drive mechanical design of stack components from concept to prototyping, testing, validation, scale-up and industrialization, with emphasis on fluid/pressure assemblies, sealing, manifolding and thermal management.

Qualifications

• Bachelor’s degree in mechanical engineering; master’s degree is a plus.
• 8–10 years in mechanical design of complex industrial products; closer to 8 years preferred.
• Experience designing assemblies with fluids, thermal, pressure, sealing and manufacturability.
• Hands-on with 3D CAD, drafting, dimensioning and tolerance analysis for complex assemblies.
• Strong Creo, SolidWorks and CAD tools; able to interpret FEA/CFD results for design.

Responsibilities

• Own mechanical design and development of multi-MW alkaline electrolyser stacks and subassemblies.
• Create 3D models, drawings, GD&T, BOMs and ECNs for stack components.
• Ensure mechanical integrity, leak-tight sealing and uniform flow/temperature distribution.
• Perform structural, thermal and flow analyses; evaluate failure risks via solid methods.
• Collaborate with electrochemistry, systems, manufacturing, QA, and supply chain teams.
• Lead prototype builds, design reviews, verification plans and root-cause analysis.
• Develop validation fixtures, testing plans and data-driven design iterations.
• Work with suppliers to achieve DFM, DFA, cost optimization and scalable production.
• Select materials/coatings suitable for electrolyser environments and long life.

Skills

Fluid & pressure-bearing assemblies

Stack architecture

Compression systems

Sealing & manifolding

Structural design

Thermal management

Tolerance stack-up

Materials selection

Design for manufacturability

Creo / CAD tooling

Education

Bachelor’s degree in mechanical engineering

Master’s degree (advantage)

Tools

Creo

SolidWorks

PLM

3D CAD

FEA / CFD collaboration

Job description

• We are seeking a highly capable Senior Mechanical Design Engineer to support the design and development of alkaline electrolyser stacks for large scale industrial hydrogen production systems, with a focus on multi-MW class electrolyser stack as product platform.
• This role will drive the mechanical design of critical stack components and subassemblies from concept development and detailed design through prototyping, testing, validation, scale-up and industrialization.
• The ideal candidate should bring in strong hands-on experience in complex fluid and pressure-bearing assemblies, including stack architecture, compression systems, sealing, manifolding, structural design, thermal management, tolerance stack-up, materials selection, and design for manufacturability.

• We are seeking a highly capable Senior Mechanical Design Engineer to support the design and development of alkaline electrolyser stacks for large scale industrial hydrogen production systems, with a focus on multi-MW class electrolyser stack as product platform.
• This role will drive the mechanical design of critical stack components and subassemblies from concept development and detailed design through prototyping, testing, validation, scale-up and industrialization.
• The ideal candidate should bring in strong hands-on experience in complex fluid and pressure-bearing assemblies, including stack architecture, compression systems, sealing, manifolding, structural design, thermal management, tolerance stack-up, materials selection, and design for manufacturability.

Key Responsibilities

• Own the mechanical design and development of multi-MW scale industrial alkaline electrolyser stack, electrolysis cells and related components, subassemblies such as end plates, cell frames, tie-rod or compression systems, elastic elements, manifolds, separators, electrodes, seals & gaskets, flow distribution features, structural & electrical interfaces.
• Develop 3D CAD models, detailed drawings, GD&T, tolerance stack-ups, bill of materials, and engineering change documentation for stack and stack subcomponents.
• Own the design of stack hardware to achieve mechanical integrity, uniform compression, leak-tight sealing, uniform flow & temperature distribution, manufacturability, serviceability, and long-term durability under operating conditions.
• Perform engineering analyses including structural analysis, tolerance analysis, thermal considerations, flow distribution assessment, and failure risk evaluation using analytical methods and simulation tools such as FEA and CFD.
• Collaborate closely with electrochemistry, systems engineering, manufacturing, quality, supply chain, and testing teams to ensure stack design meets performance, reliability, cost, and schedule targets.
• Drive prototype build, design reviews, verification planning, root cause analysis, and failure investigation during development, qualification, and field feedback loops.
• Define and execute design validation plans for mechanical components and assemblies, including fixture development, test support, and data-driven design iterations.
• Partner with suppliers and manufacturing teams to ensure design for manufacturability, design for assembly, cost optimization, and production scalability.
• Support selection of materials, coatings, and corrosion-resistant design approaches suitable for electrolyser service environments and long-life operation.
• Contribute to compliance with relevant codes, standards, and safety requirements applicable to electrolyser products and hydrogen systems.

Required Qualifications

• Bachelor’s degree in mechanical engineering; a master's degree is an advantage.
• 8 to 10 years of relevant professional experience in mechanical design and development of complex industrial products; experience closer to 8 years is strongly preferred.
• Demonstrated experience in designing mechanical assemblies involving fluids, thermal, pressure, sealing, structural loading, and manufacturability.
• Strong hands-on experience with PLM, 3D CAD, drafting, dimensioning, and tolerance analysis for complex assemblies.
• Strong hands-on experience of Creo, SolidWorks and other CAD tools is mandatory.
• Working knowledge of FEA and CFD, or the ability to effectively collaborate with analysis specialists and interpret results for design decisions.
• Experience with prototyping, testing, troubleshooting, root cause analysis, failure analysis and iterative design improvements.
• Strong understanding of DFM and DFA, supplier collaboration, and transition from prototype to pilot or production hardware.
• Excellent communication and collaboration skills, with the ability to work independently & effectively in a cross-functional product development environment.

Preferred Qualifications

• Prior experience in alkaline electrolyser systems, fuel cell, electrolyser stack, electrochemical reactors, or related hydrogen or clean energy hardware design and development.
• Experience with pressure vessel adjacent or pressure containing hardware, gasketed joints, structural frames, engineering polymers, compression systems, and leak-tight assemblies.
• Familiarity with hydrogen system safety, electrolyser related standards, and applicable codes such as ISO 22734, CSA or ANSI B22734, NFPA 2, NFPA 55, and emerging ASME guidance for electrochemical cell stacks.
• Experience with Design FMEA, DVP and R, design reviews, first article inspection, change management, and quality planning.
• Exposure to corrosion resistant materials or coatings, wet alkaline environments, and long-life industrial product development.