Senior Mechanical Design Engineer - Metal Structures at Mainspring Energy

Menlo Park, California, United States -

Full Time

Start Date

Immediate

Expiry Date

29 May, 26

Salary

156000.0

Posted On

28 Feb, 26

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Sheet Metal Design, FEA Analysis, Tolerance Stack-up Analysis, SolidWorks, PDM, DFM, Fastener Selection, Joint Design, Cyclic Loading, Thermal Loading, Vibration Analysis, Acoustic Analysis, DFMEA, Procurement, Fabrication, Testing

Industry

Electric Power Generation

Description

Company Overview Mainspring Energy is revolutionizing power generation with the world’s most flexible and adaptable local power generation technology, the Mainspring Linear Generator. Commercial, industrial, and utility leaders are choosing Mainspring over traditional options like engines, turbines, and fuel cells to quickly and reliably deliver local power for EV charging, commercial facilities, data centers, and grid-scale operations. The Mainspring Linear Generator is fuel flexible, ramps up and down to meet demand, and utilizes a flameless reaction with near-zero NOx emissions. Backed by top-tier investors including Khosla Ventures, Bill Gates, American Electric Power, Lightrock, and General Catalyst Mainspring designs, manufactures and delivers its products to customers across the U.S. today, and we’re quickly scaling for international expansion. Inspired by our vision of the affordable, reliable, net-zero carbon grid, Mainspring is rapidly expanding within the $816B global electricity equipment market, and we’re hiring the best talent to meet growing customer demand around the globe. We welcome a broad range of backgrounds, experiences, and talents to bring fresh perspectives and ongoing innovation to our customers. We are looking to build relationships with people who share our values: Pragmatic Optimism. Building a new category of world-class power generation requires the optimism of ambition and creativity, balanced with practicality to solve problems efficiently. The challenges that arise are opportunities for growth. Excellence without Ego. We bring expertise and commitment to creating the best customer experience, from sales to deployment and service, just as we apply deep technical rigor to building and delivering world-class products. We strive for excellence and behave as leaders with the humility to acknowledge our challenges, both collectively and as individual contributors. Proactive Collaboration. The integration and cross-disciplinary nature of Mainspring’s business requires intentionally seeking out others who bring different skills, perspectives, and priorities. Our culture of inclusion and respect extends beyond our team to interactions with our partners and customers. More information can be found at www.mainspringenergy.com Senior Mechanical Design Engineer - Metal Structures Mainspring is looking for Senior Mechanical Design Engineers with a focus on designing sheet metal components and assemblies. In this role, you will be responsible for developing and improving designs, overcoming DFM challenges, managing vendors, procuring and testing parts, and ensuring high-quality execution across all phases of product development. The ideal candidate will have a strong combination of technical expertise and the drive to solve complex problems in a collaborative environment. \n Core responsibilities Contribute to brainstorming and technical review sessions to develop solutions that improve performance, cost-efficiency, and reliability of the Linear Generator. Take ownership of the design, analysis, testing, and optimization of structural systems, with attention to cost, safety, and reliability trade-offs. Apply sheet metal and joint design knowledge to support development of complex assemblies with efficient manufacturing processes. Perform FEA analyses by breaking down complex loading conditions into solvable problems to inform design improvements. Conduct tolerance stack-up analysis to support robust and manufacturable designs. Use CAD tools to create detailed drawings and 3D models, maintaining accuracy in design and documentation. Support procurement, fabrication, and testing of parts, contributing to hands-on validation and iterative development. Collaborate closely with manufacturing, NPI, test, and reliability teams to ensure designs meet performance, manufacturability, and quality goals. Interface with vendors and suppliers to support quality manufacturing and timely delivery. Participate in DFMEA processes to help identify and mitigate potential failure modes. Manage tasks and priorities effectively, supporting delivery of key engineering milestones. Degree: BS or MS in Mechanical Engineering or a similar engineering field from an accredited institution. Experience and degree will determine the level, with the following minimum requirements: 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 an awareness of vibration and acoustic challenges. Proven track record contributing to complex projects by helping define requirements, evaluating technical trade-offs, identifying risks, and supporting key decisions to meet functional and performance goals. Detail-oriented, with experience generating and reviewing drawings, bills of materials, tolerance stack-ups, work instructions, and test documentation. Proficient in SolidWorks and PDM (or similar CAD version control systems), with experience using FEA and CFD tools such as SolidWorks Flow Simulation or Ansys. Familiarity with forming analysis tools to catch DFM challenges early is a plus. Comfortable working 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 and capable of delivering high-quality design work in a fast-paced environment. Experience across the full product development cycle—from concept through manufacturing support—is valued. Enthusiastic about supporting and sharing knowledge with peers and junior engineers. Passion for creating innovative and cost-effective solutions to enable the large-scale deployment of zero-carbon energy technologies. \n $132,000 - $156,000 a year This position is onsite at our Menlo Park HQ. The salary will be adjusted to reflect local market conditions based on employee location as well as the experience of the employee. Along with the base salary, Mainspring offers pre-IPO stock options + benefits. \n Does your experience not meet all of our posted requirements? Studies have shown that some people are less likely to apply to positions unless they meet every listed requirement. At Mainspring, we are committed to building a diverse, inclusive, flexible, and collaborative environment, so if you want to help us transition the world to clean and affordable electricity, and don’t meet all posted requirements for a particular role, we’d still love to hear from you. Mainspring can sometimes be flexible enough to shift responsibilities for the right person, or otherwise identify open or upcoming roles that may better fit your professional background. In more traditional words, Mainspring Energy, Inc is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, or protected veteran status and will not be discriminated against on the basis of disability. This compensation and benefits information is based on Mainspring Energy's estimate as of the date of publication and may be modified in the future. We generally do not negotiate on salary once we have made an offer. The level of pay within the range will depend on a variety of job-related factors that may include location, relevant prior experience and/or education, or particular skills and expertise. New hires joining the company tend to be paid within the starting base pay range noted above, with opportunities to increase pay over time based on development of additional skills, competencies, and company-specific knowledge.

Responsibilities

The engineer will contribute to developing solutions to improve the Linear Generator's performance, cost-efficiency, and reliability while taking ownership of the design, analysis, testing, and optimization of structural systems. Key tasks include applying sheet metal and joint design knowledge, performing FEA, conducting tolerance stack-up analysis, and creating detailed CAD documentation.