Senior Mechanical Engineer - Thermal & Air Systems

We are looking for a hands-on Senior Mechanical Engineer to join our Core Technology team, focused on the design and development of hot air handling systems for high-temperature energy storage applications. This role is central to delivering robust ducting networks, plenum assemblies, dampers, louvers, and associated air-distribution equipment that operate reliably at elevated temperatures. The ideal candidate combines analytical depth with design and assembly knowledge, and a passion for solving complex thermal-fluid engineering challenges.

What You'll Do

Responsibilities include but are not limited to:

• Lead the mechanical design of hot air ducting systems, plenum assemblies, and air distribution components operating at temperatures up to 1000 °C.
• Design, specify, and validate dampers (isolation, control, backdraft, and diverter types) and louvers for high-temperature service, including actuator selection and leakage performance requirements.
• Design plenum assemblies, transition pieces, expansion joints, and support structures that accommodate thermal growth while maintaining structural integrity.
• Define subsystem requirements and develop verification and validation (V&V) plans aligned with system-level performance, safety, and operational goals.
• Prepare technical documentation-drawings, specifications, and engineering calculations-for internal teams, fabricators, and external stakeholders.
• Perform thermal and fluid analyses to identify key design drivers; use FEA where required to confirm mechanical performance under thermal and pressure loads.
• Lead and contribute to FMEA activities to identify and mitigate risk; develop and execute test strategies, including design of experiments (DOE), to validate system performance and reliability.
• Support prototyping, test plans, vendor qualification, and iterative development across high-temperature metallic and insulated duct assemblies.
• Lead the air circulation sub-system for product development of Rondo's current and next generation product line. Follow Rondo product development phase gate process, lead Rondo product development reviews and maintain phase gate documentation.
• Develop top level system architecture for Rondo Heat Battery Air Management and Heat Delivery systems.
• Lead and participate in design reviews, schedule planning, and cross-functional progress reporting to drive program execution.
• Utilize CAD and PLM tools (SolidWorks preferred) for design, documentation, and configuration control of air-system components.
• Collaborate with manufacturing, construction, and supply chain teams to improve quality, establish process controls, and resolve root causes of field failures.
• Develop duct sizing, routing, and layout using first-principles pressure drop calculations and 1D flow network analysis, ensuring compliance with velocity, pressure, and thermal expansion requirements.
• Solve coupled multiphysics problems involving heat transfer (conduction, convection, radiation), fluid flow, and structural behavior in high-temperature air systems.

What You'll Bring

• Bachelor's or Master's degree in Mechanical Engineering or a related discipline.
• 7+ years of engineering experience with a focus on air systems, industrial gas handling, or high-temperature process systems; energy industry experience preferred.
• Proven track record of taking designs from concept through fabrication and commissioning for one or multiple of following systems: Dampers, actuators, louvers, ducts, plenum, furnace.
• Experience with high temperature equipment design. Experience with high-temperature materials: stainless steels, Inconel, refractory linings, ceramic fiber insulation, and high-temperature expansion joint materials.
• Knowledge of relevant codes and standards (e.g., API, ASME, NFPA, applicable EN standards for industrial ducting and pressure equipment).
• Strong cross-functional collaboration and communication skills; ability to work effectively with construction, commissioning, and operations teams.
• Demonstrated commitment to engineering rigor, quality documentation, and schedule execution.
• Track record of driving cost reduction through design optimization and standardization.
• Experience mentoring and developing junior engineers with authenticity and care.

Bonus Points!

• Experience working in an industrial construction environment (site supervision, field engineering).
• Ability to perform CFD analysis on duct networks, plenums, and damper assemblies.
• Familiarity with refractory-lined or high temperature ceramic fiber ductwork design and installation practices.
• Experience integrating high-temperature blower or fan systems with duct networks.
• Background in damper-actuator design, heat recovery systems, waste heat utilization, thermal-mechanical systems or thermal energy storage applications.

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.