Mechanical Engineer I

plugpower; City of Rochester (NY); On-site; USD 66,000 - 99,000; Full time

Job summary

Plug Power in Rochester, NY is seeking an entry-level Mechanical Engineer I to support ELX and PEM stack programs at the Rochester Gigafactory & Innovation Center. The role blends hands-on lab work with core engineering fundamentals, including stack teardown, test method development, and data collection.

You will work under senior engineers to set up test stands from 1 kW to 1 MW, perform DFMEA, CAD modeling (Creo), and documentation.

Qualifications

• BS degree in Mechanical Engineering or related field.
• 0–2 years of relevant experience; co-ops, internships, senior design projects, or academic lab work involving fuel cells, electrolyzers, electrochemistry, or hands-on mechanical testing are a strong plus.
• Exposure to PEM fuel cell or electrolyzer stack hardware, testing, or teardown/failure analysis is desirable but not required.
• Basic familiarity with 3D CAD modeling and drawings (Creo/Windchill a plus).
• Interest in or exposure to GD&T, FEA/CFD, and DFMEA methodology.
• Comfortable working hands-on in a lab environment with test equipment, tooling, and chemical handling.
• Strong documentation skills - able to record and communicate test results, observations, and findings clearly in lab notebooks and written reports.
• Proficiency with standard computer tools (Word, Excel, PowerPoint, Outlook, data logging/analysis software).
• Strong communication skills (written and verbal) and ability to work effectively in cross-functional teams.
• Self-motivated, detail-oriented, and eager to learn new processes and technical areas in a fast-paced environment.
• Ability to work out of Plug Power's Rochester Innovation Center; ability to travel for business need up to 10% of the time.

Responsibilities

• Support ELX and FC stack failure-analysis activities, including stack disassembly/teardown, inspection, root cause investigation, and sample preparation for downstream analytical teams
• Operate, troubleshoot, and support 1 kW, 9 kW, 15 kW, 50 kW, and 1 MW PEM test stands and associated data acquisition systems; provide day-to-day test station support to keep stations running and generating quality data
• Set up and execute standard and non-standard test procedures for PEM FC and ELX components and stacks as directed by senior engineers
• Partner with engineering and lab staff to develop new lab capabilities - new teardown procedures, test protocols, fixtures, tooling, and data collection/reporting methods - to expand the team's testing and failure-analysis capacity
• Record, organize, and analyze test and teardown data; prepare clear documentation, reports, and presentations summarizing findings, root causes, and recommendations
• Support engineering design activities for stack components and test fixtures from concept through prototype, including basic 3D CAD modeling, drawings, and bills of materials (Creo preferred)
• Assist with Design Failure Mode and Effect Analyses (DFMEA) and design reviews for stack hardware and test fixtures
• Collaborate cross-functionally with manufacturing, quality, and analytical teams to resolve stack build, test, and reliability issues
• Maintain lab equipment, tools, and test fixtures; support calibration, inventory management, and OSHA-compliant lab safety practices, including chemical handling, lock-out/tag-out, and PPE requirements
• Support engineering studies, investigations, and continuous improvement initiatives across the stack test and teardown lab
• Represent Plug Power in a professional manner at all times and in all interactions
• Perform all other duties as assigned

Skills

Lab testing

3D CAD modeling

Data analysis

Documentation

Cross-functional teamwork

Strong communication

Education

BS in Mechanical Engineering

Tools

Creo/Windchill

Data logging software

Job description

Mechanical Engineer I - Stack Engineering

Location: Rochester, NY

Department: MDEV Lab

Status: Exempt (Salaried)

Position Summary

In this entry-level engineering role, you will support Plug Power's electrolyzer (ELX) and PEM fuel cell (FC) stack programs at the Rochester Gigafactory & Innovation Center. The role blends hands-on lab work - stack teardown and failure-analysis support, test stand operation, and day-to-day station support - with the engineering fundamentals needed to design, troubleshoot, and improve stack hardware and test methods. You will support ELX and FC stack failure-analysis teardowns, execute and help develop test procedures across 1 kW to 1 MW FC and ELX test stands, and partner with engineers and technicians to stand up new lab capabilities - new teardown protocols, test methods, fixtures, and data collection tools - that expand the team's testing and failure-analysis capacity. This is an excellent opportunity for a recent mechanical engineering graduate or early-career engineer to build deep, hands-on expertise with fuel cell and electrolyzer hardware while developing the core engineering skills - CAD, DFMEA, root cause analysis, and design documentation - needed to grow into a Mechanical Engineer II role. The ideal candidate is curious, hands-on, detail-oriented, and eager to learn across both the lab and engineering sides of stack development.

Core Duties and Responsibilities

• Support ELX and FC stack failure-analysis activities, including stack disassembly/teardown, inspection, root cause investigation, and sample preparation for downstream analytical teams
• Operate, troubleshoot, and support 1 kW, 9 kW, 15 kW, 50 kW, and 1 MW PEM test stands and associated data acquisition systems; provide day-to-day test station support to keep stations running and generating quality data
• Set up and execute standard and non-standard test procedures for PEM FC and ELX components and stacks as directed by senior engineers
• Partner with engineering and lab staff to develop new lab capabilities - new teardown procedures, test protocols, fixtures, tooling, and data collection/reporting methods - to expand the team's testing and failure-analysis capacity
• Record, organize, and analyze test and teardown data; prepare clear documentation, reports, and presentations summarizing findings, root causes, and recommendations
• Support engineering design activities for stack components and test fixtures from concept through prototype, including basic 3D CAD modeling, drawings, and bills of materials (Creo preferred)
• Assist with Design Failure Mode and Effect Analyses (DFMEA) and design reviews for stack hardware and test fixtures
• Collaborate cross-functionally with manufacturing, quality, and analytical teams to resolve stack build, test, and reliability issues
• Maintain lab equipment, tools, and test fixtures; support calibration, inventory management, and OSHA-compliant lab safety practices, including chemical handling, lock-out/tag-out, and PPE requirements
• Support engineering studies, investigations, and continuous improvement initiatives across the stack test and teardown lab
• Represent Plug Power in a professional manner at all times and in all interactions
• Perform all other duties as assigned

Education and Experience

• BS degree in Mechanical Engineering or a related engineering field (required)
• 0-2 years of relevant experience; co-ops, internships, senior design projects, or academic lab work involving fuel cells, electrolyzers, electrochemistry, or hands-on mechanical testing are a strong plus
• Exposure to PEM fuel cell or electrolyzer stack hardware, testing, or teardown/failure analysis is highly desirable but not required
• Basic familiarity with 3D CAD modeling and drawings (Creo/Windchill a plus)
• Interest in or exposure to GD&T, FEA/CFD, and DFMEA methodology
• Comfortable working hands-on in a lab environment with test equipment, tooling, and chemical handling
• Strong documentation skills - able to record and communicate test results, observations, and findings clearly in lab notebooks and written reports
• Proficiency with standard computer tools (Word, Excel, PowerPoint, Outlook, data logging/analysis software)
• Strong communication skills (written and verbal) and ability to work effectively in cross-functional teams
• Self-motivated, detail-oriented, and eager to learn new processes and technical areas in a fast-paced environment
• Ability to work out of Plug Power's Rochester Innovation Center; ability to travel for business need up to 10% of the time

Pay Rate:

$66,000.00 - $99,000.00

We offer a fantastic total rewards package at Plug, and a brief summary is below:

• Base salary is determined on a number of factors including but not limited to education, experience, skills, and geography. These factors are considered when making an offer of employment.