Senior Staff Mechanical Engineer (Module)

Every day shows the increasing need for low-cost, reliable, and safe energy sources. Solar and wind are now the most economic sources of electricity. The challenge is affordable energy storage. An electrical grid powered by renewables requires massive investments in energy storage technologies. Lithium-ion batteries have been deployed on the grid, but the world needs solutions that are lower cost with longer lifetime and better safety, and which are not limited by raw materials availability and foreign supply chains. 

At Inlyte, we are driven by a deep-seated hope based on human potential. Our team is transforming the proven sodium metal chloride battery technology into a solution to meet the energy needs of today. Made of iron and sodium, our energy storage systems are built from naturally abundant and inexpensive raw materials. Proven benefits include:

  • Low cost materials and manufacturing
  • Safe, durable in extreme temperatures, long-lifetime, with high round-trip efficiency
  • Domestically-sourced production without supply chain constraints

Inlyte Energy is backed by top tier VCs along with large industrial strategic investors and includes the pioneers and world experts on sodium metal chloride batteries on its team.

Role and Responsibilities

We are looking for a Senior Staff Mechanical Engineer with deep expertise in the design and manufacturing of battery modules to lead and grow Inlyte’s module engineering team. As both a technical lead and manager of the module engineering team, you’ll own the end-to-end mechanical and thermal design of battery module enclosures, internal structures, interconnects, and integration features, while working closely with cell, electrical, systems, manufacturing, and supply chain teams to bring our modules from prototype to production. This is a once-in-a-career opportunity to define and scale a product backed by 40+ years of research in order to shape the electrical grid of tomorrow.

This position reports to the VP of Engineering. This is an on-site role located in the Bay Area. For the first 6 months, the role will require extensive travel to Inlyte’s pilot cell and module manufacturing facility in the UK. Thereafter the role will require about 10-25% travel to the UK and to Inlyte’s US factory.  For this role you will: 

  • Own the end-to-end mechanical design of battery modules — including enclosures, structural framing, fastening, interconnects, and electrical interfaces.
  • Lead the module engineering team initially as a hands-on technical lead and eventually as a manager of the larger team that you will build as Inlyte grows.
  • Develop mechanically and thermally optimized designs that meet demanding requirements for shock, vibration, ingress protection, thermal performance, safety, and long-term durability.
  • Drive design for manufacturability and assembly (DFM/DFA) from concept through production release — including tolerance stackups, cost optimization, and high-volume production techniques (e.g., stamping, casting, laser welding, automated assembly).
  • Collaborate with manufacturing engineering and suppliers to develop assembly processes, tooling/fixtures, process flow documentation, and quality inspection methods.
  • Conduct structural simulations (FEA) to inform design decisions and de-risk failure modes under load, thermal cycling, and transport conditions.
  • As the company’s module engineering lead, own development timelines, lead design reviews, own mechanical documentation, and manage change control for modules across product development cycles.
  • Interface directly with supply chain, quality, and CM partners to align on requirements, DFM feedback, part qualification, and ramp planning.
  • Partner with system integration, cell design, and validation teams to ensure mechanical and electrochemical compatibility across system interfaces.
  • Support early validation builds and resolve manufacturing non-conformances, deviations, and yield issues in real-time.

Minimum Qualifications

  • Bachelor’s degree in Mechanical Engineering or related field.
  • 10+ years of experience in mechanical design for battery modules, automotive systems, industrial enclosures, or similar high-power thermo/electro-mechanical assemblies.
  • Proven track record designing products for production at scale, including NPI, pilot, and ramp phases.
  • Previous experience managing engineering teams.
  • Deep knowledge of sheet metal, metal casting, injection molding, and joining techniques (welding, adhesives, fasteners).
  • Demonstrated success working with manufacturing partners, resolving design/process issues, and driving cost/performance tradeoffs.
  • Expertise in 3D CAD (e.g., SolidWorks, NX) and drawing generation for supplier release.
  • Experience with tolerance analysis, GD&T, and mechanical verification testing.
  • Effective communicator and a good listener with integrity.
  • Entrepreneurial mindset with the ability to thrive in a dynamic startup environment.
  • A champion of our Practices of Safety, Determination, Teamwork, Humility, and Joy.


Preferred Qualifications

  • M.S. or Ph.D. in Mechanical Engineering or related field.
  • Familiarity with battery safety regulations and testing protocols (e.g., UL9540, UN38.3, IP ratings).
  • Experience designing seals, enclosures, and cooling interfaces for outdoor or industrial systems.
  • Proficiency in FEA tools (e.g., ANSYS, Abaqus) for structural and thermal simulations.
  • Previous experience with automated assembly design, DFMEA, and PPAP/FAI documentation.


Benefits

  • Incentive stock options based on Bay Area comps regardless of location
  • Medical, vision, and dental insurance and short term disability (100% of employee’s insurance premium and 75% of dependants)
  • 40 hours of paid sick time
  • Hybrid commute option for Bay Area employees
  • Unlimited PTO policy
  • Compensation range for Bay Area: $160,000 - $200,000 depending on qualifications and experience

     

We celebrate diversity and are committed to creating an inclusive community. We encourage you to apply even if you do not meet all of the qualifications.


Principals only - no recruiters please.

Engineering

Hybrid (San Leandro, California, US)

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