Sr. Mechanical Engineer, Electrolyzer Stack Design

Fourier is working on making on-site Hydrogen universally accessible. Our breakthrough architecture enables highly modular and fully automated electrolyzers that scale to any size and optimize efficiency at all loads. We are on a mission to transition the global energy landscape towards a purely sustainable and emission free future. 

About the Role

As a Senior Mechanical Engineer specializing in stack design for PEM electrolyzers, you will play a pivotal role in selecting, developing, and optimizing stack components for fluid flow distribution. Working closely with the stack team, you will iterate designs, prototype, and scale them for production while contributing to the overall stack design. This role requires deep technical expertise, a bias towards action, and a collaborative approach in a fast-paced environment.

Roles and responsibilities

• Lead the design, development, testing, and validation of critical stack components such as fluid flow distribution plates, cell frames, seals, and bipolar plates while ensuring alignment with stack performance targets.

• Apply in-depth knowledge of materials and coatings used in PEM electrolyzer stack components.

• Optimize fluid flow distribution and heat transfer within the stack, using knowledge of thermodynamics, two-phase flow analysis, and computational techniques like FEA and CFD to maximize stack performance and durability.

• Analyze and optimize compression settings to ensure robust sealing performance and uniform compression under various operating conditions and lifespans.

• Perform stack-up tolerance analysis to ensure high precision in assembly and operation.

• Collaborate with suppliers and internal teams to design stack components suited for injection molding, sheet metal stamping, etching, CNC machining, and applying anticorrosive and conductive coatings.

• Ensure designs are manufacturable at scale while meeting quality, cost, and performance standards.

• Troubleshoot and conduct root cause analysis of stack issues during prototype and production stages, resolving any field failures.

• Develop and implement testing methods and protocols to validate stack component designs and identify areas for performance and durability improvements.

• Design fixtures, jigs, and other tools to visualize and improve flow distribution within the stack during component selection.

Qualifications

• BS or preferably MS or PhD in Mechanical Engineering, Chemical Engineering, Material Science, or a related field.

• Minimum 5 years of experience, preferably in PEM electrolyzers, fuel cells, or related fields.

• Proven track record in taking complex components from concept to manufacturing and troubleshooting field failures.

• Experience in stack tolerance analysis, design validation, and supplier collaboration.

• Expertise in FEA, CFD, and fluid flow visualization.

• Deep understanding of manufacturing processes such as injection molding, sheet metal stamping, etching, and coatings.

• Knowledge of thermodynamics, fluid flow distribution, and heat transfer in stack designs.

What we offer

• Fully paid Medical, Dental, and Vision coverage

• Competitive salary and equity compensation commensurate with experience

• 401k

• Diverse and inclusive work environment

• Paid sick days and vacation