Sr. Development Engineer

Posted One Month Ago
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New Britain, PA, USA
In-Office
Senior level
Greentech • Energy • Chemical
We are a climate solutions company leading the next generation of carbon technology.
The Role
Develop first-principles process simulations and mechanistic models for reactions, separations, and integrated SAF production; apply modeling and data analytics to support scale-up and process design; convert lab/pilot results into engineering design inputs; lead experiments and pilot campaigns to validate models and de-risk commercialization; collaborate cross-functionally to advance technology to commercial deployment.
Summary Generated by Built In

About AIRCO

AIRCO™ develops advanced technologies for energy security and global resiliency. The company makes drop-in e-fuels that can power transportation across air, land, sea and space. Its modular MAD Fuel System™ combines the company's proprietary catalysts, compact hardware, and locally available power to produce fuels to spec wherever they’re needed, turning distributed energy into ready-to-use fuel.
Led by co-founder and CEO Gregory Constantine (a 2026 EY Entrepreneur of the Year), the company has been awarded government contracts, including from the U.S. Department of War, NASA and the Department of Energy (DoE), and has investment and commercial partners with groups such as In-Q-Tel, GE Aerospace, Toyota Ventures, Virgin Atlantic, JetBlue and Alaska Airlines among others. 

What you get to do 

  • Develop and maintain first-principles process simulations and mechanistic models for reaction, separation, and integrated SAF production systems.
  • Apply modeling, simulation, and data analytics to predict performance, support scale-up decisions, optimize process design, and reduce commercialization risk.
  • Convert laboratory and pilot-scale results into Engineering Design Information (EDI), process design inputs, and technology performance projections.
  • Lead the development of experimental strategies and pilot campaigns required to validate models, resolve technical uncertainties, and strengthen scale-up confidence.
  • Partner with cross-functional teams to advance technology from development through demonstration and commercial deployment, while identifying opportunities for innovation and process improvement.

What you bring to AIRCO

  • M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a closely related discipline
  • Significant experience in process development, process modeling, simulation, and scale-up engineering within chemical process industries.
  • Strong grounding in thermodynamics, reaction engineering, and separation fundamentals
  • Demonstrated ability to analyze large datasets and extract mechanistic insight, not just empirical fits
  • Advanced experience with numerical tools, simulation software, or data analysis platforms (e.g., Aspen, MATLAB, Python, similar)
  • Demonstrated experience developing first-principles, mechanistic, or hybrid process models for chemical reaction and separation systems. 
  • Experience applying simulation and modeling tools to technology scale-up, process design, and commercialization decisions. 
  • Ability to bridge experimental observations and engineering models to generate predictive process understanding.
  • Proven ability to use engineering fundamentals, experimental data, and simulation tools to diagnose process behavior and resolve technical challenges.
  • Experience in fuels, petrochemicals, refining, catalysis, or sustainable energy technologies
  • Familiarity with scale-up challenges, process modeling, and commercialization workflows
  • Experience supporting or delivering EDI / FEL engineering packages

Working at AIRCO - In addition to standard medical and dental benefits, that kick in Day 1, we provide:

Comprehensive Health Benefits

  • Full coverage for employee base premiums on health, dental, and vision insurance.
  • 70% coverage for spouse and dependent base premiums.
  • Choose between base plans or enhanced options to fit your needs.

Health Savings & Flexibility

  • Access company-sponsored HSA and FSA accounts to save on healthcare and dependent care expenses.

Income Protection & Insurance

  • Company-paid Short-Term Disability insurance.
  • Optional Long-Term Disability and Life Insurance plans.

Time Off & Leave

  • Flexible and generous paid time off, with opportunities to carry over unused PTO.
  • Paid family leave to support you during important life moments.

Retirement Savings

  • Tax-deferred 401(k) plan with a 3% company match to help you invest in your future.

Lifestyle & Commuter Benefits

  • Monthly Lifestyle Spending Account: Company-funded monthly benefit that can be used toward eligible work-from-home and commuting expenses, including gas, parking, and public transit.
  • Pre-Tax Commuter Benefits: Access to pre-tax savings through Navia for eligible transit and parking expenses.

Additional Perks

  • Ancillary benefits through Sequoia, including pet insurance and financial wellness programs.
  • Employee wellness program to support your well-being. Inclusive of Wellhub & One Medical. 
  • Company-sponsored events and programs that promote an inclusive and values-driven workplace.
  • Weekly company-funded meal stipend that can be used toward meals from restaurants and food delivery services.

At AIRCO we value employees for their unique perspectives. We are an inclusive affirmative action Equal Employment Opportunity employer. We consider applicants without regard to actual or perceived race, color, creed, religion, national origin, ancestry, citizenship status, age, sex or gender (including pregnancy, childbirth, pregnancy-related conditions, and lactation), gender identity or expression (including transgender status), sexual orientation, marital status, military service and veteran status, present or past history of intellectual, learning, mental, or physical disability (including but not limited to blindness) unless AIRCO determines that such disability prevents performance of the work involved, genetic information, or any other characteristic protected by applicable federal, state, or local laws and ordinances.

Don’t meet every single requirement? Studies have shown that women, marginalized genders and people of color are less likely to apply to jobs unless they meet every single qualification. At AIRCO we are dedicated to building a diverse, inclusive and authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every qualification in the job description, we encourage you to apply anyways. You may be just the right candidate for this or other roles

This position requires access to technology, software and other information that is subject to governmental access control restrictions, due to export controls, security classification and/or designation as Controlled Unclassified Information. Employment in this position is conditioned on the candidate’s ability to obtain and maintain appropriate government authorization to access technology or information, to the extent required, including without limitation a security clearance, export license, or other documentation required to establish authorization to receive access to such items technology or information.

We may delay commencement of employment, rescind an offer of employment, terminate employment, and/or modify job responsibilities, compensation, benefits, and/or access to Company facilities and information systems, as we deem appropriate, in order to ensure compliance with applicable government access control restrictions.

I consent to transfer my data to Air Company in the U.S. and to its use in accordance with the Air Company Privacy Policy, and I opt in to receiving information from Air Company. Air Company does not sell or share personal information to third parties within the meanings given under applicable laws. 

Skills Required

  • M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or closely related discipline
  • Significant experience in process development, process modeling, simulation, and scale-up engineering within chemical process industries
  • Strong grounding in thermodynamics, reaction engineering, and separation fundamentals
  • Demonstrated ability to analyze large datasets and extract mechanistic insight
  • Advanced experience with numerical tools, simulation software, or data analysis platforms (e.g., Aspen, MATLAB, Python)
  • Experience developing first-principles, mechanistic, or hybrid process models for chemical reaction and separation systems
  • Experience applying simulation and modeling tools to technology scale-up, process design, and commercialization decisions
  • Ability to bridge experimental observations and engineering models to generate predictive process understanding
  • Proven ability to use engineering fundamentals, experimental data, and simulation tools to diagnose process behavior and resolve technical challenges
  • Experience in fuels, petrochemicals, refining, catalysis, or sustainable energy technologies
  • Familiarity with scale-up challenges, process modeling, and commercialization workflows
  • Experience supporting or delivering Engineering Design Information (EDI) / Front-End Loading (FEL) engineering packages
  • Ability to obtain and maintain government authorization or security clearance and comply with export controls as required

AIR COMPANY Compensation & Benefits Highlights

The following summarizes recurring compensation and benefits themes identified from responses generated by popular LLMs to common candidate questions about AIR COMPANY and has not been reviewed or approved by AIR COMPANY.

  • Healthcare Strength — The benefits package is described as strong on health coverage, including medical, dental, and vision starting Day 1 with the employer covering most or all employee premiums in several listings. Additional health-related support like One Medical membership and disability/life insurance is also included.
  • Retirement Support — A 401(k) benefit is described with a stated company match in some materials, alongside other financial benefits like pre-tax accounts. This provides a baseline retirement savings mechanism that can add meaningful value beyond base pay.
  • Wellbeing & Lifestyle Benefits — Lifestyle-oriented benefits include commuter benefits, free daily meals/snacks, wellness programming, and company-sponsored events. These perks can improve day-to-day affordability and overall quality of life.

AIR COMPANY Insights

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The Company
HQ: New York, NY
89 Employees
Year Founded: 2017

What We Do

Since 2017, our mission has been to address the dramatic surge in atmospheric carbon levels by utilizing CO2 as a climate solution. We’re united by our drive to move society towards a more sustainable future by creating innovative solutions that directly curb the emissions that affect climate change. We do this by using technology that converts CO2 into the highest quality and most sustainable fuels and alcohols on the planet — helping to decarbonize entire industries from aviation to beauty.

Why Work With Us

We are people-first. We're a unified team of climate optimists with an exceptional and diverse range of backgrounds. From scientists and engineers to product developers and beyond, the collective at AIR COMPANY is one that is ever-evolving.

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