Principal Mechanical Engineer – Energy Infrastructure Projects

ON.energy is building the power infrastructure that makes the AI era possible. The Principal Mechanical Engineer will serve as a senior individual contributor in design, analysis, and validation activities, focusing on mechanical standards and product reliability within the engineering organization.

Responsibilities:

• Perform and oversee structural stress, fatigue, and vibration analysis for mechanical assemblies, enclosures, and supporting infrastructure across ON.Energy's product portfolio
• Lead or review FEA models and reports to validate mechanical designs under static, dynamic, thermal, and seismic loading conditions
• Ensure mechanical and structural safety under operational loads, transportation loads, and applicable environmental conditions
• Evaluate failure modes and translate findings into design improvements that enhance product durability, reliability, and lifecycle performance
• Lead thermal design activities for enclosures, including HVAC and fluidics sizing calculations, temperature limit identification, humidity management, and mitigation strategies
• Validate cooling and heating system performance across a range of environmental conditions, including extreme heat, cold, high humidity, and coastal/saline environments
• Develop simulation-backed recommendations for thermal and environmental design improvements using FEA/CFD tools
• Establish and maintain mechanical engineering specifications, analytical processes, and validation methodologies that govern hardware development and deployment
• Develop and implement new processes or engineering specifications with measurable impact on product quality, structural safety, and field reliability
• Ensure designs are validated against applicable codes and standards (e.g., IBC, ASCE 7, NFPA, IEC, UL) and that compliance is documented throughout the design lifecycle
• Collaborate with BESS, Power Electronics, and Controls teams to ensure integrated system-level mechanical performance
• Participate in product design sprints and stage-gate reviews as a structural and mechanical SME, identifying risks before they reach the field
• Provide technical input during design iterations based on lessons learned from project engineering, installation, commissioning, and O&M activities
• Support development and review of mechanical documentation including calculations, reports, specifications, and as-built drawings
• Communicate structural risks, design decisions, and engineering trade-offs clearly to both technical teams and non-technical stakeholders, including engineering leadership and external clients
• Willing to travel up to 20% to support product FAT inspections and site commissioning witnessing

Requirements:

• Bachelor's degree in Mechanical Engineering or related technical field
• 12+ years of hands-on structural and mechanical engineering experience in product-based, project-based, or industrial settings
• Strong experience performing stress analysis, fatigue analysis, and vibration assessment on mechanical assemblies and enclosures
• Demonstrated experience with thermal design of enclosures, including HVAC system design and environmental management
• Proficiency with FEA tools (e.g., SolidWorks Simulation, ANSYS) for structural and thermal validation
• Proven ability to develop or improve mechanical standards and processes with tangible impact on product outcomes
• Ability to interpret engineering drawings and develop detailed calculations and technical reports
• Strong communication skills across both technical and non-technical audiences
• Experience in battery energy storage, medium voltage UPS, power conversion, power generation, or mission-critical infrastructure
• Panel building mechanical design experience for power and controls/IT equipment
• Familiarity with seismic zone design requirements and site-specific structural compliance
• Master's degree in Mechanical Engineering or related field