Staff Mechanical Engineer – Continuous Improvement for Mechanical Design & Quality Control

Job Overview

Do you have a knack for design of complex mechanical systems? Have you ever invented a tool or changed a process just to make routine installation or service faster and easier? If you're driven by solving real-world design challenges, and working with state of the art mechanical power generation equipment, then this role is built for you.

Mainspring Energy is seeking a Mechanical Sustaining Engineer with a focus on design to lead product improvement efforts across our field and production systems. You will work embedded on site at a contract manufacturer to address design and manufacturing issues at their root. You will support manufacturing with a hands-on approach to solve complex dynamic mechanical problems working directly with the product to take measurements, perform testing, and support pilot efforts to develop rework/retrofit processes.  You will redesign critical components for durability and ease of service, and integrate your findings back into the development process to ensure the long-term reliability and manufacturability of our products. 

Core Responsibilities

Lead the root cause analysis of mechanical failures using data from diagnostics, hands-on testing, and fundamental analysis of bolted joints or material fatigue life

Redesign or re-engineer components, fasteners, or assemblies to eliminate failures, reduce costs, or improve serviceability

Coordinate design engineering, manufacturing, and quality teams to ensure that changes are thoroughly tested and validated with short feedback cycles

Collaborate with NPI, manufacturing quality, and supply chain teams to ensure solutions are optimized for production, vendor capabilities, and field service

Predict and prevent failure modes by applying a deep understanding of mechanical system interactions, tolerance stack-ups, and real-world use conditions

Implement feedback loops from field issues into design standards and engineering processes to continuously improve product quality and reduce recurrence

Manage internal improvement systems that embed learnings into manufacturing process flow and future design development efforts

Support the development of service tooling, testing fixtures, or diagnostic aids as needed for improved deployment and serviceability

Travel to HQ in Menlo Park, CA required once per quarter

Qualifications

BS or MS in Mechanical Engineering or a similar technical field, minimum BS + 11 years mechanical design experience

Hands-on experience with mechanical design, including analysis of bolted joints, stress analysis, and structural integrity

Hands on experience with component and system level testing including measurement techniques and data analysis

Proven ability to use data-driven root cause analysis to solve complex, cross-functional design issues.

Experience addressing and resolving field and production issues

Knowledge of DFM/DFA principles and quality system tools (PFMEA, 8D, CAPA, etc.)

Deep understanding of tolerance stack-ups and the use of CMMs in inspection processes

Familiar with manufacturing processes including tube swaging, crimping, potting, stamping, sheet metal, hydroforming, welding, machining, and fabrication

Proficient in SolidWorks or a comparable CAD package; PDM experience preferred

Experience with structural FEA and/or is a plus

A passion for building robust, field-ready solutions with high reliability and serviceability

Why Join Us?

Directly influence the reliability and field performance of mission-critical mechanical systems

Collaborate with top-tier engineering teams in a fast-paced and supportive environment

Be part of an innovation-driven company working on impactful technologies

Competitive compensation and a full benefits package

Opportunities for technical leadership and long-term growth

Join Our Mission

We’re committed to building a diverse and inclusive team and welcome candidates from all backgrounds. Even if you don’t meet every requirement, if this role resonates with your skills and passions, we encourage you to apply.