Senior Mechanical Design Engineer - Structures & Insulation

We are looking for a highly skilled Senior Mechanical Design Engineer to join our team. This role leads the design and development of high-temperature insulation systems, structural interfaces, and sealing solutions for complex thermal systems. The ideal candidate combines strong mechanical design and thermomechanical expertise with hands-on experience taking integrated hardware from concept through validation and production.

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

• Lead the mechanical design and validation of components, assemblies, and systems subjected to repeated thermal cycling and operating temperatures up to 1500 °C.

• Develop high-temperature insulation systems and assemblies using metals, ceramics, refractories, and other appropriate materials.

• Design and validate mechanical interfaces, compliant mechanical features, and sealing solutions that accommodate differential thermal expansion while maintaining structural integrity and environmental isolation, in collaboration with the structural engineering team.

• Perform 1D heat- and mass-flow analyses to identify design-driving factors and inform system-level decisions.

• Conduct FEA to evaluate and validate mechanical and thermomechanical performance.

• Contribute to and lead design and process FMEA activities.

• Develop component-level test methodologies and design experiments to validate performance and reduce technical risk.

• Use CAD and PLM software—SolidWorks preferred—for design, documentation, and configuration control.

• Develop clear, testable subsystem requirements.

• Prepare technical documentation for external suppliers and internal stakeholders.

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

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

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

What You’ll Bring:

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

• 7+ years of relevant mechanical engineering experience involving complex mechanical systems.

• Proven experience taking mechanical designs from concept through qualification and high volume production.

• Demonstrated design experience with high-temperature materials, thermomechanical systems, and mechanical interfaces for high-voltage systems.

• Proficiency in FEA and 1D thermal analysis.

• Experience applying GD&T principles and connecting critical features and tolerance stack-ups to functional performance.

• A commitment to schedule execution, high-quality documentation, and engineering rigor.

• A track record of applying sound engineering judgment to evaluate requirements, challenge assumptions, and recommend scope, cost, or technical tradeoffs to meet performance and schedule objectives.

• Excellent technical leadership, communication, and cross-functional collaboration skills.

Bonus Points:

• Experience performing CFD analysis.

• Knowledge of relevant electrical and mechanical design standards and considerations, including creepage and clearance, arc-flash protection, and ingress protection.

• Experience supporting field installation or commissioning of complex industrial or energy systems.

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 necessitates being on-site at our Alameda HQ several times per week. The estimated annual salary range for this role is $170,000 to $200,000 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.