Senior Mechanical Design Engineer, Sheet Metal & Structures

Mainspring Energy, Inc.; Menlo Park (CA); On-site; USD 140,000 - 165,000; Full time

Benefits offered by this job

Restricted Stock Units (RSUs)

Benefits package

Job summary

Mainspring Energy, Inc in Menlo Park, CA is seeking a Senior Mechanical Design Engineer focused on sheet metal structures to advance the Linear Generator platform. You will own the design, analysis, testing, and optimization of structural systems, balancing performance, manufacturability, and reliability across the product lifecycle.

Applicants should have a BS/MS in Mechanical Engineering with 6+ years experience in sheet metal design, familiarity with SolidWorks/PDM, and hands-on prototyping.

Qualifications

• BS or MS in Mechanical Engineering required; Senior: BS+6 years or MS+5 years
• Strong knowledge of sheet metal design, manufacturing processes, fastener selection, joint design, coatings, and assembly practices
• Experience designing for durability under cyclic and thermal loading with vibration/acoustic awareness
• Proven track record contributing to complex projects by defining requirements, evaluating trade-offs, risks, and decisions
• Detail-oriented with experience generating drawings, BOMs, tolerance stack-ups, work instructions, and test documentation
• Proficient in SolidWorks and PDM, with experience using FEA/CFD tools such as SolidWorks Flow Simulation or Ansys
• Familiarity with forming analysis tools to catch DFM challenges early
• Hands-on with prototyping, testing, and failure analysis of structural components
• Experience working cross-functionally with manufacturing, supply chain, test and reliability teams
• Self-motivated with the ability to deliver high-quality design in a fast-paced environment
• Passion for innovative, cost-effective solutions enabling large-scale zero-carbon energy deployment

Responsibilities

• Own design, analysis, testing, and optimization of structural systems with a focus on cost, safety, and reliability
• Apply sheet metal and joint design knowledge to complex assemblies for manufacturability
• Perform FEA analyses to inform design improvements
• Contribute to tolerance stack-up analyses for robust designs
• Create detailed drawings and 3D models with accurate documentation
• Support procurement, fabrication, and testing of parts
• Collaborate with manufacturing, NPI, test, and reliability teams to meet goals
• Interface with vendors to ensure quality manufacturing and timely delivery
• Participate in DFMEA processes to mitigate failure modes
• Manage tasks and milestones across the engineering pipeline

Skills

Sheet metal design

SolidWorks

FEA/CFD tools

Cross-functional collaboration

Prototyping & testing

PDM

Education

BS/MS in Mechanical Engineering

Tools

SolidWorks

Ansys

CFD tools

PDM

Job description

Mainspring Energy, Inc in Menlo Park, CA is seeking a Senior Mechanical Design Engineer focused on sheet metal structures to advance the Linear Generator platform. You will own the design, analysis, testing, and optimization of structural systems, balancing performance, manufacturability, and reliability across the product lifecycle.

Applicants should have a BS/MS in Mechanical Engineering with 6+ years experience in sheet metal design, familiarity with SolidWorks/PDM, and hands-on prototyping.