Senior Mechanical Engineer

We are looking for a highly skilled Senior Mechanical Design Engineer to join our Core Technology team focused on high-temperature, high voltage energy storage systems. This role involves leading the design and development of ceramic, refractory, and insulation assemblies, as well as mechanical and electrical interfaces critical to thermal systems. The ideal candidate combines deep technical expertise with hands-on experience bringing complex mechanical designs from concept to production.  

What You’ll Do (responsibilities include but are not limited to):

• Lead the mechanical design of components, assemblies, and systems operating at temperatures up to 1500 °C

• Solve complex multiphysics design challenges involving heat transfer, fluid flow, and structural behavior in extreme environments.

• Design and validate high-voltage heating elements and electrical interfaces (e.g., busbars, bolted joints), accounting for thermal, electrical, and mechanical to ensure reliability, safety, and compliance

• Design for high-energy fault conditions, including arc flash risk, through appropriate geometry, insulation coordination and clearances

• Design and validate insulation systems, including ceramic and refractory components, for thermal performance, durability, and manufacturability

• Perform thermal, mass flow and mechanical analysis to identify key design drivers and validate performance

• Define subsystem requirements and develop verification and validation strategies aligned with system-level performance goals

• Lead and contribute to FMEA activities, drive risk identification, mitigation, and design robustness

• Develop and support the execution of test strategies, including design of experiments (DOE) and specialized test setups, to validate design performance, reliability, and safety

• Support rapid prototyping and iterative development across ceramics, refractories, metals

• Lead design reviews, schedule planning, and cross-functional communication to drive program execution

• Apply GD&T principles to ensure functional performance through tolerance analysis and robust design

• Utilize CAD and PLM tools (SolidWorks preferred) for design, documentation, and configuration control

• Generate clear technical documentation for internal teams, suppliers, and external stakeholders

• Collaborate closely with manufacturing and supply chain to improve yield, establish process controls, and resolve root causes of failures

What You'll Bring:

•  Bachelor’s or Master’s degree in Mechanical Engineering or a related discipline.

• 7+ years of engineering experience across multiple industries and technologies; energy systems experience preferred

• Proven track record of taking designs from concept through high-volume production

• Demonstrated expertise in high-temperature materials, thermal-mechanical systems, and high-voltage applications

• Strong knowledge of relevant electrical and mechanical compliance standards (e.g., creepage and clearance, arc flash, ingress protection)

• Familiarity with refractory manufacturing processes and high-temperature wire fabrication

• Proficiency in FEA and 1D thermal analysis

• Deep understanding of GD&T, tolerance stack-ups, and core mechanical design principles

• Strong cross-functional collaboration and communication skills

• Demonstrated commitment to engineering rigor, quality documentation, and schedule execution

• Track record of driving cost reduction through design optimization

Bonus Points!

• Experience in a construction environment 

• Experience performing CFD analysis

• Experience mentoring and developing junior engineers

What We Offer:

• Comprehensive Medical Benefits
• Dental & Vision Benefits
• Life Insurance and ADD
• Up to 13 paid holidays per year, in addition to a company week-long holiday in December
• Flexible time off policy
• Catered lunches on-site
• 401(k) plan with company match
• Rondo HQ is close to Oakland airport - one block from the Bay - and has stunning Bay views!

This role is on-site, and necessitates being present at our Alameda HQ 4-5 days per week. The estimated annual salary range for this role is $150,000 to $180,000 and it would be eligible for Rondo's excellent benefits listed above plus additional compensation in the form of equity. Please note that some pay bands may have wide ranges of compensation to accommodate candidates' diverse sets of skill levels and experience.

About the Company  

We are transforming industrial decarbonization with our innovative Rondo Heat Battery technology. Rondo is deploying low-cost, zero-carbon Rondo Heat Batteries to accelerate the deployment of renewable energy and to significantly decarbonize industrial processes that are commonly thought of as "difficult-to-decarbonize". Our heat batteries charge from intermittent renewables to provide high temperature, continuous heat for customers safely, reliably, at an unprecedented 98% efficiency - and at a cost point that is lower than any other method.  

Our technology is designed to replace fossil-fired boilers. By enabling industries to adopt renewable energy without costly factory changes, we are accelerating the transition to a sustainable future. With over $160 million in funding and partnerships across critical industrial sectors, Rondo is scaling rapidly to meet global demand.

Rondo Energy is an equal opportunity employer. We strive to create a supportive and inclusive workplace where contributions are valued and celebrated, and our employees thrive by being themselves and are inspired to do their best work. We seek applicants of all backgrounds and identities, across race, color, ethnicity, national origin or ancestry, citizenship, religion, sex, sexual orientation, gender identity or expression, veteran status, marital status, pregnancy or parental status, or disability. Applicants will not be discriminated against based on these or other protected categories or social identities.

Rondo is committed to the full inclusion of all applicants. If reasonable accommodation is needed to participate in the interview process, please let our recruiting team know.

We proactively work to design hiring processes that promote equity and inclusion while mitigating bias.

Note to Recruitment Agencies: Rondo does not accept unsolicited agency resumes. Furthermore, Rondo Energy does not pay placement fees for candidates submitted by any agency other than its approved partners.