Mechanical Engineer 1 - Stack Engineering

Mechanical Engineer I – Stack Engineering

Status: Exempt (Salaried)

Department: MDEV Lab

Location: Rochester, NY

Position Summary

In this entry-level engineering role, you will support Plug Power’s electrolyzer (ELX) and PEM fuel cell (FC) stack programs at the Rochester Gigafactory & Innovation Center. The role blends hands-on lab work — stack teardown and failure-analysis support, test stand operation, and day-to-day station support — with the engineering fundamentals needed to design, troubleshoot, and improve stack hardware and test methods.

You will support ELX and FC stack failure-analysis teardowns, execute and help develop test procedures across 1 kW to 1 MW FC and ELX test stands, and partner with engineers and technicians to stand up new lab capabilities — new teardown protocols, test methods, fixtures, and data collection tools — that expand the team’s testing and failure-analysis capacity.

This is an excellent opportunity for a recent mechanical engineering graduate or early-career engineer to build deep, hands-on expertise with fuel cell and electrolyzer hardware while developing the core engineering skills — CAD, DFMEA, root cause analysis, and design documentation — needed to grow into a Mechanical Engineer II role. The ideal candidate is curious, hands-on, detail-oriented, and eager to learn across both the lab and engineering sides of stack development.

Core Duties and Responsibilities

• Support ELX and FC stack failure-analysis activities, including stack disassembly/teardown, inspection, root cause investigation, and sample preparation for downstream analytical teams

• Operate, troubleshoot, and support 1 kW, 9 kW, 15 kW, 50 kW, and 1 MW PEM test stands and associated data acquisition systems; provide day-to-day test station support to keep stations running and generating quality data

• Set up and execute standard and non-standard test procedures for PEM FC and ELX components and stacks as directed by senior engineers

• Partner with engineering and lab staff to develop new lab capabilities — new teardown procedures, test protocols, fixtures, tooling, and data collection/reporting methods — to expand the team’s testing and failure-analysis capacity

• Record, organize, and analyze test and teardown data; prepare clear documentation, reports, and presentations summarizing findings, root causes, and recommendations

• Support engineering design activities for stack components and test fixtures from concept through prototype, including basic 3D CAD modeling, drawings, and bills of materials (Creo preferred)

• Assist with Design Failure Mode and Effect Analyses (DFMEA) and design reviews for stack hardware and test fixtures

• Collaborate cross-functionally with manufacturing, quality, and analytical teams to resolve stack build, test, and reliability issues

• Maintain lab equipment, tools, and test fixtures; support calibration, inventory management, and OSHA-compliant lab safety practices, including chemical handling, lock-out/tag-out, and PPE requirements

• Support engineering studies, investigations, and continuous improvement initiatives across the stack test and teardown lab

• Represent Plug Power in a professional manner at all times and in all interactions

• Perform all other duties as assigned

Education and Experience

• BS degree in Mechanical Engineering or a related engineering field (required)

• 0–2 years of relevant experience; co-ops, internships, senior design projects, or academic lab work involving fuel cells, electrolyzers, electrochemistry, or hands-on mechanical testing are a strong plus

• Exposure to PEM fuel cell or electrolyzer stack hardware, testing, or teardown/failure analysis is highly desirable but not required

• Basic familiarity with 3D CAD modeling and drawings (Creo/Windchill a plus)

• Interest in or exposure to GD&T, FEA/CFD, and DFMEA methodology

• Comfortable working hands-on in a lab environment with test equipment, tooling, and chemical handling

• Strong documentation skills — able to record and communicate test results, observations, and findings clearly in lab notebooks and written reports

• Proficiency with standard computer tools (Word, Excel, PowerPoint, Outlook, data logging/analysis software)

• Strong communication skills (written and verbal) and ability to work effectively in cross-functional teams

• Self-motivated, detail-oriented, and eager to learn new processes and technical areas in a fast-paced environment

• Ability to work out of Plug Power’s Rochester Innovation Center; ability to travel for business need up to 10% of the time

Pay Rate:

$66,000.00 - $99,000.00

We offer a fantastic total rewards package at Plug, and a brief summary is below:

✓Base salary is determined on a number of factors including but not limited to education, experience, skills, and geography. These factors are considered when making an offer of employment. If you are interested in this position, we’d ask that you apply.

✓The above pay range, may not take into account local geographic pay variations. If there is an applicable geographic differential, a member of the HR team can discuss that with you.

✓Health, Dental & Vision Insurance eligibility starting from the first day of hire

✓401(k) with 5% company match

✓Bonus eligibility

✓Paid time off including vacation, personal and sick time

✓Paid Holidays

✓Wellness Reimbursement Program

✓Potential to apply for Tuition Reimbursement

✓Fertility and Family Building Benefit

✓Employee Referral program

✓Employee Assistance Program

Plug Power Inc. is committed to creating a diverse environment and is proud to be an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, or veteran status.