Job Description

About the Company

Calion is a venture-backed and ARPA-E/CEC funded U.S. technology and manufacturing startup that is developing and commercializing pioneering ionocaloric refrigeration and heat pumping technologies to enable non-hazardous and zero-global-warming potential cooling and heating. Greenhouse gas emissions from current refrigeration and heat pumping technologies are on track to contribute up to 0.5 degrees of global warming by 2100. We need talented, hardworking individuals who share our goal of tackling the refrigerant problem so that we can cool the planet down, one-less-refrigerant-at-a-time. Our patented electrochemical cell architecture that drives the cooling cycle is approaching pilot scale, and we’re expanding the hardware team to accelerate scale‑up.

About the Role

You’ll drive the mechanical design, process development, and manufacturability of our electrochemical separator stack—from benchtop prototypes through pilot‑line runs and contract manufacturing. Working hand‑in‑hand with electrochemists, process engineers, mechanical engineers, and external suppliers, you’ll translate lab concepts into robust, cost‑effective hardware that ships.

Responsibilities

• Architect & model complex electrochemical flow geometries—including manifolds, flow fields, and sealing schemes—using SolidWorks (or equivalent) and CFD/FEA tools.
• Develop scale‑up processes (extrusion, casting, lamination, laser/water‑jet cutting) and design‑for‑manufacture/assembly (DFM/A) guidelines for plastics, composites, and coated metals.
• Specify materials (polymers, elastomers, corrosion‑resistant alloys, coatings) compatible with harsh chemical environments; validate via accelerated life‑testing.
• Design fluid‑handling subsystems—pumps, valves, heat exchangers, degassing hardware—optimized for high‑density and oxidizing electrolytes and two‑phase flow.
• Create & execute test plans (pressure, burst, leak, thermal cycling), analyze failure modes, and iterate quickly toward reliability targets (10 000+ hours).
• Lead cross‑functional reviews and drive supplier engagement, cost modeling, and build schedules to hit program milestones.
• Mentor junior engineers and establish best‑practice documentation (drawings, specs, BOMs, SOPs).

Qualifications

• B.S./M.S. in Mechanical Engineering or related field + 8 yrs (min) of hardware product development;

Required Skills

• Expert 3‑D CAD and GD&T; strong fundamentals in structural mechanics, heat transfer, and multiphase fluid dynamics.
• Familiarity with FEA and CFD (COMSOL, ANSYS, or similar) for stress, thermal, and flow distribution analyses.
• Proven DFM/A track record for molded plastics or composite parts and precision‑machined components.
• Clear technical communication, project planning, and vendor negotiation skills.
• Demonstrated track record in rapid prototyping.
• General Machining Skills (CNC/Lathe/Waterjet/etc).

Preferred Skills

• Experience with flow‑battery or electrolyzer manifolds, fuel cells, or other relevant 2D stackable electrochemical technologies.
• Python/LabVIEW/PLC scripting for data acquisition and test‑stand control.
• Exposure to techno‑economic or cost‑down analysis for electrochemical hardware.
• Patent drafting or freedom‑to‑operate assessments.

Pay range and compensation package

135k-200k Annual Salary

Why Join?

• Mission impact – Tackle one of the biggest decarbonization challenges in cooling.
• Ownership – Significant responsibility and equity in a fast‑growing startup.
• Resources – World‑class advisors, well‑equipped lab, and non‑dilutive funding to move fast.

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