Staff Mechanical Design Engineer

We are looking for a highly skilled Staff 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 that are cycled and maintained at high temperatures up to 1500 °C.

• Design and validate ceramic, refractory, and insulation parts and assemblies  

• Design heating elements and high-temperature electrical joints for reliability, manufacturability, constructability, and compliance

• Execute 1D heat and mass flow analyses to identify design-driving factors and perform CFD (Ansys Fluent, StarCCM etc) for detailed analysis

• Conduct FEA to analyze and confirm expected mechanical performance

• Contribute to and lead FMEA activities

• Apply advanced GD&T principles, linking critical features to tolerance stack-ups and functional performance.

• Perform tolerance analysis, including thermal expansion effects   

• Develop component test methodologies and design of experiments (DOE) 

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

• Formulate robust subsystem requirements

• Prepare documentation as needed for outside suppliers and stakeholders

• Collaborate with manufacturing and supply chain teams to improve yields, establish process controls, and resolve root cause of failures

• Support rapid prototyping efforts across ceramics, refractories, metals, and plastics

• Lead and participate in design reviews, schedule estimation, and progress reporting to cross-functional teams 

What You'll Bring:

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

• 10+ years of engineering experience from multiple industries and technologies, energy industry a plus

• Proven experience taking designs from concept through to production at volume

• Demonstrated design experience with high-temperature materials, thermal-mechanical systems, and high voltage systems

• Knowledge of electrical and mechanical compliance standards such as creepage and clearance, arc flash protection, and ingress protection

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

• Proficiency in FEA, 1D thermal analysis, and CFD

• Expertise in GD&T, tolerance stack-ups, and mechanical design fundamentals

• Strong communication and collaboration skills; able to work cross-functionally and empower others.

• Commitment to schedule adherence, quality documentation, and engineering rigor

• Track record of successful cost reduction initiatives and designs

• Authenticity and care in mentoring more junior engineers 

• Excellent leadership and communication skills

Bonus Points!

• Experience performing 2D and 3D tolerance stack-ups

• Experience in a construction environment 

This role is required to be on-site at our Alameda Headquarters with up to 10% travel to project sites. The estimated annual salary range for this role in the San Francisco Bay Area is $180,000 to $225,000 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 Rondo Energy

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.