Mechanical Engineering Lead

Polymer; Cambridge (MA); On-site; USD 180,000 - 240,000; Full time

Benefits offered by this job

Competitive salary

Stock options

Medical insurance

Dental insurance

Vision benefits

401k match

Commuter benefits

Job summary

Sora Fuel in Cambridge, MA seeks a Principal Mechanical Engineer to lead the mechanical design and fabrication of a FOAK Sustainable Aviation Fuel pilot plant. You will own the electrolyzer architecture as the project scales from prototype to pilot, coordinating internal teams and external vendors.

The role requires deep expertise in electrochemical systems, 3D CAD, FEA, and manufacturing methods, plus a proactive safety mindset and strong cross-functional communication.

Qualifications

• MS in Mechanical Engineering required.
• 15+ years of progressive mechanical engineering experience.
• Experience designing and scaling electrochemical systems or related tech.
• GD&T, fabrication methods, and safety compliance knowledge.

Responsibilities

• System Architecture: mechanical design, layout, and integration of the carbonate electrolysis system.
• Scale-Up Engineering: translate bench-scale designs into functional pilot plant.
• Thermal & Fluid Systems: design piping, manifolds, and thermal loops.
• Vendor & Fabricator Management: oversee external EPCs and machine shops.
• Safety & Compliance: ensure adherence to ASME and industry codes.
• Hands-on Assembly & Commissioning: build, test, and commission the pilot plant.

Skills

Leadership

Mechanical design

Fabrication knowledge

GD&T

SolidWorks

FEA

Safety mindset

Communication

Vendor management

Education

Master of Science in Mechanical Engineering

Tools

SolidWorks

FEA

Job description

Sora Fuel

Sora Fuel aims to decarbonize aviation by converting air into affordable, carbon-neutral jet fuel at scale with no feedstock constraints or adverse impacts on agriculture. Our novel electrolysis technology directly converts captured carbon into syngas without regenerating gaseous CO2, reducing the energy required to utilize DAC-sourced CO2 by up to 90%. This provides an economical pathway to carbon-neutral flight, potentially addressing >2% of challenging-to-abate global emissions.

The company was founded in early 2024 and has closed over $20M of funding from renowned toughtech investors including Engine Ventures, Spero Ventures, and Inspired Capital. Since founding, the team has grown to include scientists and engineers with a broad range of skill sets from electrochemistry and catalysis to polymer science and mechanical engineering. Together, this team has scaled our technology >800-fold, demonstrated a true prototype employing commercial-scale cells, and developed scalable manufacturing processes for key materials. We seek to continue building a diverse, collaborative team that shares our enthusiasm and drive to meaningfully address climate change.

Role

Sora is seeking a visionary Principal Mechanical Engineer to spearhead the mechanical design, engineering, and fabrication of our First-of-a-Kind (FOAK) Sustainable Aviation Fuel (SAF) pilot plant. In this role, you will lead the physical realization of an integrated facility that combines novel Direct Air Capture (DAC) technology with a cutting-edge carbonate electrolysis system. You will own the electrolyzer mechanical architecture as we transition from our prototype system to a pilot system. You will take the design from concept through physical fabrication and commissioning, turning advanced chemical workflows into robust, operational industrial systems. As our Principal Mechanical Engineer, you will bridge the gap between complex electrochemical/chemical processes and robust industrial machinery. This is a role requiring deep technical expertise, a get it done mindset, and the ability to lead external vendors and lead and mentor internal team members

Required Qualifications & Experience

• Education: Master of Science (MS) in Mechanical Engineering

• Experience: 15+ years of progressive mechanical engineering experience, with a proven track record of taking complex physical systems from concept to successful field operation.

• Technical Domain Expertise: Direct prior experience designing and scaling electrochemical systems, grid-scale battery systems, or closely related multi-phase physical-chemical technology.

• Manufacturing Fluency: Deep knowledge of diverse fabrication methods (machining, welding, sheet metal, custom casting) and geometric dimensioning and tolerancing (GD&T).

• CAD Mastery: Expert proficiency in 3D modeling and product data management software (e.g., SolidWorks) alongside Finite Element Analysis (FEA) for stress and thermal optimization.

• Safety Mindset: Must anticipate risks, speaking up about hazards, and prioritize long-term safety over short-term speed.

• Communication: Ability to communicate effectively and work in a fast-paced, collaborative team environment.

• Core Values: Alignment with our core values of transparency, diversity, collaboration, valuing people and development, and work ethic.

Preferred Skills

• Familiarity with carbon capture equipment, electrochemical cells, or chemical process piping (ASME B31.3).

• Background in skid design and modular industrial plant layouts.

• Process Equipment Knowledge: Experience selecting and integrating industrial balance-of-plant components, including pumps, compressors, heat exchangers, and high-purity piping systems.

• Startup Agility: Prior experience working in fast-paced, venture-backed hardware startups or highly innovative R&D environments.

Key Responsibilities

Mechanical Design and Engineering

• System Architecture: Responsible for the mechanical design, layout, and structural integration of the carbonate electrolysis system.

• Scale-Up Engineering: Translate bench-scale and custom-component designs into a fully functional, containerized, or skid-mounted industrial pilot plant.

• Thermal & Fluid Systems: Design and optimize piping, custom manifolds, fluid delivery networks and thermal management loops.

• Vendor & Fabricator Management: Select, vet, and manage external EPCs, machine shops, and component suppliers to ensure rapid, high-quality fabrication.

• Cross-Functional Leadership: Partner closely with Chemical Engineers, Chemists,

• Mechanical and Electrical to ensure flawless mechanical-to-process integration.

• Safety & Compliance: Must have a safety mindsetOversee compliance with relevant

• pressure vessel, piping, and industrial safety codes (e.g., ASME B31.3, ASME Section VIII).

• Hands-on Assembly & Commissioning: Build, test, troubleshoot, and commission the pilot plant alongside the field team.

• Testing & Validation: Formulate test plans, mechanical commissioning procedures, and safety checklists for newly fabricated platforms.

• Analysis: Analyze physical test data to iterate and optimize subsequent hardware designs.

Benefits

• Competitive salary

• Incentive Stock Options

• Medical, dental, and vision benefits

• 401k match

• Commuter benefits