Mechanical Design Engineer III - Wilsonville, OR, US

Catalyzing a cleaner future. · ESS is a globally recognized leader in sustainable energy storage and is consistently identified as one of the most innovative and exciting technology players in energy storage. It is poised to be one of the fastest growing energy technology compani ...

Job description

Catalyzing a cleaner future.

ESS is a globally recognized leader in sustainable energy storage and is consistently identified as one of the most innovative and exciting technology players in energy storage. It is poised to be one of the fastest growing energy technology companies in the world, with projects already across 4 continents and an upcoming public offering. The ESS vision is about enabling the decarbonization of the grid by enabling us to achieve up to 100% of our electricity from clean, sustainable renewable energy. These are ambitious goals, and we are pursuing them with passion. At ESS, we are leading the energy transition, creating the sustainable energy solutions of the future to help individuals, businesses and communities change energy into lasting value.

ESS is seeking a dynamic Mechanical Design Engineer with a strong background in mechanical design, thermodynamics, fluid flow and structural analysis. The role will focus on R&D of ESS's advanced battery power module technology to ensure performance, reliability and cost. The deliverables will require significant input into the mechanical design: structural and fluidic analysis, testing and validation, prototyping, specification creation and implementation, quality support, etc. The ideal candidate will have a passion for sustainability and the environment, will thrive in a fast-paced entrepreneurial setting, be self-motivated, and have an interest in disruptive, cutting-edge technology.

What you'll do at ESS:

• Senior contributor to the mechanical design of stack and subsystem hardware (manifolds, flow fields, plates, frames, enclosures, seals) using 3D CAD and rigorous design control (models, drawings, specs, BOMs; GD&T).
• Analyze and optimize thermal/fluid performance and structural integrity (pressure/temperature/vibration/thermal cycling) using FEA/CFD. Translate insights into robust design updates.
• Engineer for manufacturability and reliability (DFM/DFA/DFR) across casting, machining, plastics (injection molding, extrusion, plastics welding), and sealing processes (welding, adhesives, gaskets).
• Select materials compatible with electrolytes and corrosive environments; address creep, fatigue, and stress-relaxation mechanisms with appropriate safety margins and life predictions.
• Correlate models to test: develop validation plans, define test articles/fixtures, analyze data, close the loop to simulation, and drive root-cause and corrective actions.
• Collaborate across all engineering and supply chain teams to convert performance targets into durable, cost-effective designs ready for production.
• Continuously improve cost, reliability, and serviceability while maintaining safety, compliance, and quality standards.

What you bring to the table:

Minimum Requirements

• B.S. in Mechanical Engineering (or related).
• 5+ years of experience in mechanical design and analysis of complex fluid or electrochemical systems (or equivalent combination of graduate and industry experience).
• Proficiency in 3D CAD (Inventor, SolidWorks, or equivalent) for parametric design, detailed drawings, and BOMs.
• Strong foundation in thermodynamics, fluid mechanics, and solid mechanics, with hands-on FEA/CFD and tolerance stack-ups.
• Developed detailed engineering drawings using GD&T principles per ASME Y14.5, incorporating a strong understanding of quality inspection methods to accurately define and verify critical-to-function (CTF) and critical-to-quality (CTQ) features.
• Experience designing for corrosive or reactive fluids and hermetic sealing (welds, adhesives, gaskets).
• Track record of cross-functional execution from concept to validated hardware (proto → pilot → production).
• Clear, concise communicator; self-directed; able to juggle multiple design workstreams.
• Ability to lift 50 lbs. unassisted
• Ability to follow job required Standards and Safety Protocols, per pre-defined processes
• Must be able to wear Personal Protection Equipment according to OSHA rules and regulations

We'd love to see

• M.S. in Mechanical, Materials Science, Energy Systems, or Chemical Engineering.
• Experience in battery, fuel cell, or power-generation system design.
• Demonstrated multiphysics experience (ANSYS, COMSOL, or equivalent) and test correlation.
• Scaling from prototype to production; cost and reliability ownership.
• Knowledge of electrolyte-compatible materials and corrosion mitigation.
• Experience with pressure-bound assemblies and pressure vessel considerations.
• Plastics and polymer component design for injection molding, extrusion, and plastics welding.
• Hands-on experience with CNC/CAM and other fabrication and machining techniques, with a solid understanding of tolerances, tool paths, and manufacturability trade-offs.
• Practical understanding of material creep, fatigue, and stress relaxation, including creep and fatigue failure analysis and life prediction for polymers and metals under sustained loads, vibration, and thermal cycling.
• Programming proficiency using engineering platforms such as Python or MATLAB for design automation, data analysis, or simulation post-processing.

Benefits of working at ESS.

In addition to the value of working with and helping grow a global reaching clean technology, ESS offers a comprehensive health insurance plan (medical, dental, vision), FSA and HSA accounts, 401k with company match, flexible time off (FTO), and 8 paid holidays.

As an equal opportunity employer, we are open to considering every qualified candidate who is eligible and legally authorized to work in the United States on a full or part-time basis, without a need for sponsorship.