Senior Mechanical Engineer -- Electrochemical Systems

Calion Technologies; Berkeley (CA); On-site; USD 135,000 - 200,000; Full time

Job summary

Calion Technologies is seeking a Senior Mechanical Engineer specializing in electrochemical systems. The role involves mechanical design and process development for innovative refrigeration technologies. You will collaborate with a diverse team to bring prototype designs to manufacturing, ensuring reliability and efficiency in performance while addressing global cooling challenges.

Benefits

Significant responsibility and equity

World-class advisors and facilities

Non-dilutive funding

Qualifications

• 8+ years of hardware product development experience required.
• Required expertise in 3-D CAD and GD&T.
• Familiar with FEA and CFD tools for analyses.

Responsibilities

• Drive mechanical design and manufacturability of electrochemical systems.
• Architect & model complex electrochemical flow geometries.
• Lead cross-functional reviews and mentor junior engineers.

Skills

3-D CAD

GD&T

structural mechanics

heat transfer

multiphase fluid dynamics

project planning

vendor negotiation

technical communication

Education

B.S./M.S. in Mechanical Engineering or related field

Job description

Senior Mechanical Engineer -- Electrochemical Systems

Senior Mechanical Engineer -- Electrochemical Systems

This range is provided by Calion Technologies. Your actual pay will be based on your skills and experience — talk with your recruiter to learn more.

Base pay range

$135,000.00/yr - $200,000.00/yr

Additional compensation types

RSUs and Stock options

Direct message the job poster from Calion Technologies

CEO & Co-founder at Calion | Activate + BEF Fellow | Heating and Cooling Technologies

About the Company

Calion is a venture-backed and ARPA-E/CEC funded U.S. technology and manufacturing startup that is developing and commercializing pioneering ionocaloric refrigeration and heat pumping technologies to enable non-hazardous and zero-global-warming potential cooling and heating. Greenhouse gas emissions from current refrigeration and heat pumping technologies are on track to contribute up to 0.5 degrees of global warming by 2100. We need talented, hardworking individuals who share our goal of tackling the refrigerant problem so that we can cool the planet down, one-less-refrigerant-at-a-time. Our patented electrochemical cell architecture that drives the cooling cycle is approaching pilot scale, and we’re expanding the hardware team to accelerate scale‑up.

About the Role

You’ll drive the mechanical design, process development, and manufacturability of our electrochemical separator stack—from benchtop prototypes through pilot‑line runs and contract manufacturing. Working hand‑in‑hand with electrochemists, process engineers, mechanical engineers, and external suppliers, you’ll translate lab concepts into robust, cost‑effective hardware that ships.

Responsibilities

• Architect & model complex electrochemical flow geometries—including manifolds, flow fields, and sealing schemes—using SolidWorks (or equivalent) and CFD/FEA tools.
• Develop scale‑up processes (extrusion, casting, lamination, laser/water‑jet cutting) and design‑for‑manufacture/assembly (DFM/A) guidelines for plastics, composites, and coated metals.
• Specify materials (polymers, elastomers, corrosion‑resistant alloys, coatings) compatible with harsh chemical environments; validate via accelerated life‑testing.
• Design fluid‑handling subsystems—pumps, valves, heat exchangers, degassing hardware—optimized for high‑density and oxidizing electrolytes and two‑phase flow.
• Create & execute test plans (pressure, burst, leak, thermal cycling), analyze failure modes, and iterate quickly toward reliability targets (10 000+ hours).
• Lead cross‑functional reviews and drive supplier engagement, cost modeling, and build schedules to hit program milestones.
• Mentor junior engineers and establish best‑practice documentation (drawings, specs, BOMs, SOPs).

Qualifications

• B.S./M.S. in Mechanical Engineering or related field + 8 yrs (min) of hardware product development;

Required Skills

• Expert 3‑D CAD and GD&T; strong fundamentals in structural mechanics, heat transfer, and multiphase fluid dynamics.
• Familiarity with FEA and CFD (COMSOL, ANSYS, or similar) for stress, thermal, and flow distribution analyses.
• Proven DFM/A track record for molded plastics or composite parts and precision‑machined components.
• Clear technical communication, project planning, and vendor negotiation skills.
• Demonstrated track record in rapid prototyping.

Preferred Skills

• Experience with flow‑battery or electrolyzer manifolds, fuel cells, or other relevant 2D stackable electrochemical technologies.
• Python/LabVIEW/PLC scripting for data acquisition and test‑stand control.
• Exposure to techno‑economic or cost‑down analysis for electrochemical hardware.

Pay range and compensation package

Why Join?

• Mission impact – Tackle one of the biggest decarbonization challenges in cooling.
• Ownership – Significant responsibility and equity in a fast‑growing startup.
• Resources – World‑class advisors, well‑equipped lab, and non‑dilutive funding to move fast.

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Seniority level

• Seniority level

  Mid-Senior level

Employment type

• Employment type

  Full-time

Job function

• Job function

  Engineering and Information Technology

• Industries

  HVAC and Refrigeration Equipment Manufacturing

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