Mechanical Design Engineer

NextGenEnergyJobs; Alameda, Northern (CA, KY); Hybrid; USD 110,000 - 140,000; Full time

Job summary

NextGenEnergyJobs is seeking an on-site engineer at our Alameda headquarters to design high‑temperature components and assemblies. The role involves FEA/1D thermal analyses, rapid prototyping, and collaboration with cross‑functional teams across design and manufacturing.

The incumbent will apply GD&T, tolerance stack‑up analysis, and integrate high‑temperature sensors within assemblies, using SolidWorks and PLM workflows to maintain documentation and support suppliers.

Qualifications

• Experience designing high-temperature components and assemblies.
• Experience with FEA and thermal/fluids analysis.
• Knowledge of GD&T and tolerance stack-up methods.
• Prototyping and rapid build-test cycles.
• Experience with CAD/PLM workflows.

Responsibilities

• Design components and systems that operate at temperatures up to 1500°C.
• Perform FEA and 1D thermal/CFD analyses and support FMEA activities.
• Lead rapid prototyping and test-build iterations.
• Apply GD&T and tolerance stack-up to critical features.
• Integrate high-temperature sensors and ensure proper isolation and routing.
• Use CAD/PLM tools (SolidWorks preferred) for design and documentation.
• Prepare documentation for suppliers and stakeholders.
• Participate in design reviews and project scheduling with cross-functional teams.

Skills

High-temperature design

FEA

CAD (SolidWorks)

GD&T

Tolerance stack-up analysis

Prototype development

Thermal systems

Tools

SolidWorks

PLM software

Job description

This role is required to be on-site at our Alameda Headquarters with up to 10% travel to project sites.

Responsibilities

• Design components, assemblies, and systems — including ceramic, refractory, steel, and insulation parts — that are cycled and maintained at high temperatures up to 1500°C
• Conduct FEA and 1D thermal and fluid-flow analysis to confirm mechanical performance and correlate against test data; contribute to FMEA activities to identify and mitigate failure risks
• Drive rapid prototyping and fast build-test-learn iteration cycles to quickly validate designs and accelerate maturity
• Apply GD&T principles and tolerance stack-up analysis to critical features
• Specify and mechanically integrate high-temperature measurement devices and other sensors into the assembly — including mounting, thermal/electrical isolation, and cable routing — in collaboration with electrical and controls engineers
• Utilize CAD and PLM software (SolidWorks preferred) for design, documentation, and configuration control
• Formulate subsystem requirements and prepare documentation for external suppliers and stakeholders
• Lead and participate in design reviews, schedule estimation, and progress reporting to cross-functional teams