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Mechanical & Design Engineer II – III
On-site, Branford, CT (must be willing to relocate to the Bridgeport/Stamford area within one year of the start date)
 About Oxylus Energy
Oxylus Energy is a climate-tech company building solutions that can scale. Our breakthrough electrochemical technology converts carbon dioxide into carbon-neutral fuels and chemicals, reducing the world's dependence on fossil fuels. We are a team of scientists, engineers, and problem solvers working to make that future real.
Job brief
As Mechanical & Design Engineer, you will own the mechanical design of Oxylus’ CO₂ electrolyzer, from single cells to multi-cell stacks, along with all mechanical aspects of the balance of stack. You will turn electrochemical requirements into robust, manufacturable hardware. That covers flow fields, bipolar plates, end plates, manifolds, seals, compression systems, current collectors, and the fluid connections that integrate the stack into a test or production system.
This is a hands-on role. Beyond modeling and drawings, you will build, and test the hardware you design, working side by side with our R&D and engineering teams to diagnose problems and improve performance, durability, and scalability.
What You Will Do
Own the mechanical design of our COâ‚‚ electrolyzer cells and stacks, including flow fields, bipolar plates, end plates, manifolds, gaskets and seals, and compression hardware.
Design and specify all mechanical balance-of-stack components, including fluid connections, current collectors, insulation, and mounting and integration hardware.
Use computational fluid dynamics (CFD) to model gas and liquid flow, pressure drop, and heat transfer, and use the results to optimize designs.
Produce detailed CAD models and manufacturing drawings with appropriate tolerancing (GD&T), and manage design revisions and documentation.
Select materials for chemical compatibility, corrosion resistance, and electrical and thermal performance in an electrochemical environment.
Design and build prototype cells and stacks, run leak and pressure checks, and support electrochemical testing on our test stations.
Diagnose hardware-related failures such as leaks, uneven compression, flow maldistribution, and corrosion, and implement design fixes.
Work with machine shops and suppliers on fabrication, quotes, and quality, and design for manufacturability as we scale to larger formats.
Contribute to safety reviews of hardware that handles pressurized and hazardous gases, including CO.
Occasionally perform hands-on manufacturing process including operating of CNC machine or band saws.
Who You Are
A degree in Mechanical Engineering or a related field, with experience matching the level:
Engineer II: B.S. with 2-4 years, or M.S. with 1–2 years of relevant experience.
Engineer III: B.S. with 4+ years, M.S. with 2–4 years, or Ph.D. with 0–2 years of relevant experience
Proficiency in 3D CAD, such as SolidWorks, Creo, or NX, and in producing manufacturing drawings with GD&T.
Hands-on experience with CFD tools such as ANSYS Fluent or COMSOL.
Familiarity with electrochemical hardware development, such as electrolyzers, fuel cells, or batteries.
Hands-on experience building, and testing mechanical prototypes.
Understanding of sealing, compression, and fluid-containing vessels.
Attentive to detail, with strong problem-solving and organizational skills.
Good written, verbal, and presentation skills.
Nice to Have
Direct experience designing electrolyzer or fuel cell stacks.
Experience with structural or thermal finite element analysis (FEA).
Familiarity with pressure equipment codes and standards, such as ASME.
Experience with machining, 3D printing, or other rapid-prototyping methods.
Experience with CAM softwares.
Experience scaling hardware from lab prototypes to pilot or production designs.
Salary
Engineer II: USD 90,000–100,000 per year base salary commensurate with experience, education, and skills.
Engineer III: USD 100,000–110,000 per year base salary commensurate with experience, education, and skills.
Benefits
Competitive salary.
Medical, dental, and vision coverage
Paid sick days and vacation
401k match
A diverse and inclusive work environment
Equal opportunity
We believe the distinct contributions of each person fuel our success. To keep our products and culture inclusive of all viewpoints and experiences, Oxylus Energy does not discriminate on the basis of race, color, religion, sex, national origin, gender identity or expression, sexual orientation, age, marital status, veteran status, disability, or any other characteristic protected by law.
