Senior Mechanical Engineer - Frame and Air Spring

Mainspring Energy is seeking a talented Mechanical Engineer to join the team responsible for the design and development of the frame support structure and air spring system for our innovative Linear Generator technology. These systems are critical for maintaining our very tight alignment of subassemblies, withstanding significant structural and thermal loads during operation, and storing potential energy during part of our cycle. This is a challenging, hands-on role where your creativity, strong engineering fundamentals, and practical skills will directly contribute to making a significant impact on our clean energy solution.

Core Responsibilities

• Design and develop frame and air spring subsystems projects, including conceptualization, detailed design, 3D CAD modeling (Solidworks), engineering analysis (FEA/CFD tools like ANSYS for thermal, structural, and flow), testing, root cause investigation, and comprehensive documentation.
• Focus on challenges specific to our frame structure and air spring systems, such as achieving and maintaining a very tight alignment, design for high load transfer and fatigue durability, design for thermal management and improving system performance.
• Collaborate effectively with cross-functional teams (Controls, Manufacturing, Suppliers) to ensure seamless subsystem integration, performance, and support new product introduction (DFM/DFA, work instructions, tooling/fixtures).
• Plan and execute rigorous verification and validation testing to ensure designs meet demanding requirements (functional, durability, thermal, vibration, acoustic, safety, reliability).
• Support the continuous improvement of engineering processes, tools, standards, and best practices within the team. Provide technical guidance to technicians.
• Stay current on advancements in mechanical engineering relevant to power generation, identifying opportunities to reduce costs, improve performance, and enhance reliability as Mainspring scales its technology
• Uphold and further Mainspring's mission to create clean, affordable, and reliable power generation that accelerates the world's transition to a sustainable energy future.

Qualifications

• • Bachelor's or Master's degree in Mechanical Engineering or similar field.
  • 3+ years as a professional mechanical design engineer.
  • Delivered products through 1+ full design lifecycles from concept to manufacturing support, preferably involving industrial equipment, power generation, engine systems, or similar demanding applications.
  • Self-starter with a proven ability to deliver functional designs in a rapid development environment and a track record of innovation and continuous improvement.
  • Direct experience designing components or systems operating in high-cycle and high-load environments.
  • Demonstrated engineering fundamentals in structural mechanics and thermal design. Experience with structural analysis (FEA) is essential.
  • Direct experience designing systems with bolted joints that carry load.
  • Familiarity with design considerations for durability, fatigue, and reliability in demanding applications.
  • Proficiency in 3D CAD modeling (Solidworks preferred), engineering drawing creation (GD&T, detailed datum selection), and experience with PDM/PLM or similar CAD version control system.
  • Knowledge of mechanical design principles, materials, manufacturing processes (machining, sheet metal, welding, casting, forging), and ability to identify and resolve design for manufacturability issues.
  • Hands-on mechanical prototyping, assembly, and testing skills. Experience with relevant instrumentation (thermocouples, accelerometers, pressure sensors) is a plus.
  • Experience applying engineering analysis tools (FEA, tolerance stack ups) to solve design problems and validate concepts. Familiarity with acoustic analysis is beneficial.
  • Excellent problem-solving, creative thinking, communication, and collaboration skills for effective cross-functional teamwork.
  • Ability to work independently and manage multiple projects in a fast-paced environment.
  • Passion for clean energy and commitment to creating a more sustainable world.

$119,000 - $140,000 a year

This position is onsite at our Menlo Park HQ. The salary will be adjusted to reflect local market conditions based on employee location as well as the experience of the employee. Along with the base salary, Mainspring offers pre-IPO stock options + benefits.

Does your experience not meet all of our posted requirements? Studies have shown that some people are less likely to apply to positions unless they meet every listed requirement. At Mainspring, we are committed to building a diverse, inclusive, flexible, and collaborative environment, so if you want to help us transition the world to clean and affordable electricity, and don't meet all posted requirements for a particular role, we'd still love to hear from you. Mainspring can sometimes be flexible enough to shift responsibilities for the right person, or otherwise identify open or upcoming roles that may better fit your professional background.