Job Description We are seeking a Mechanical Engineer with deep hands-on expertise to lead mechanical design, analysis, integration, and validation of our commercial hydrogen production systems. This is a high-ownership role spanning all subunits and design aspects and the full balance-of-plant envelope that ties them together.
This role sits at the intersection of mechanical, electrical, and manufacturing disciplines. You will co-own DFM/DFA strategy with our manufacturing partners and serve as the primary mechanical interface to our electrical and electronics engineering teams - ensuring that both high-voltage (HV) power conversion systems and low-voltage (LV) control and sensing electronics are packaged safely, thermally managed, and fully integrated into production enclosures. Roles and responsibilities
Lead concept development, design trades, and down-select decisions for all mechanical subsystems from water purification through post-production H₂ purification
Own 3D CAD design of complex parts and assemblies using SolidWorks or equivalent - including sheet metal, plastics, insulation systems, sealing methods, connectors, and fasteners
Review and develop process flow diagrams, P&IDs;, and mechanical design documentation
Perform first-principles hand calculations for sizing and performance of fluid, thermal, and structural systems
Collaborate closely with the electrical and electronics engineering teams to integrate high-voltage (HV) power electronics and low-voltage (LV) control, sensing, and communications systems into mechanical enclosures
Design packaging solutions for HV electrical assemblies - including bus bars, power modules, and high-current connectors - ensuring proper insulation, creepage/clearance compliance, and thermal management
Design and validate cooling technologies (heat exchangers, forced-air systems) for thermal management of electrolyzer stacks, power electronics, and ancillary electrical components
Ensure enclosure designs meet relevant electrical safety standards (UL, IEC, NFPA) for HV systems handling DC bus voltages typical of PEM electrolysis applications
Define and manage interface control documents (ICDs) between mechanical and electrical subsystems
Partner actively with manufacturing engineering to embed Design for Manufacturability (DFM) and Design for Assembly (DFA) principles from the earliest concept phase through production release
Create and maintain full Balance-of-Plant (BoP) documentation including Bills of Materials, P&IDs;, and fluid system specifications
Hands-on experience or strong familiarity with gas (hydrogen, nitrogen, oxygen) and water piping systems, including pressure ratings, material compatibility,



and leak testing protocols
Develop test plans and lead laboratory test and validation activities to confirm product reliability, safety, and performance
Create and maintain PLM documentation including Bills of Materials, engineering drawings, design calculations, and FMEAs
Qualifications
Required:
B.S. in Mechanical Engineering or equivalent; 6+ years of relevant experience in commercial product design and development
First-principles understanding of statics, mechanics, materials science, heat transfer, thermodynamics, and fluid dynamics - with the ability to apply these rapidly in hand calculations
Extensive experience taking mechanical designs from concept through production, including prototype builds and manufacturing release
Proven experience in DFM/DFA - working hand-in-hand with manufacturing partners to optimize designs for producibility, assembly, and reliability
Demonstrated experience packaging and integrating electromechanical systems involving both HV and LV electrical components
Proficiency in 3D CAD (SolidWorks strongly preferred) and Thermal & Structural FEA tools
Strong hands-on aptitude - comfortable in the lab, on the shop floor, and at the test rig
Experience creating GD&T-compliant; 2D fabrication drawings (ASME Y14.5)
Preferred:
Advanced degree (M.S. or Ph.D.) in Mechanical Engineering or closely related field
Experience with PEM electrolysis, fuel cell systems, or related electrochemical systems
Hands-on experience with hydrogen, oxygen, nitrogen, or other high-purity gas systems - including pressure management, material selection (316L SS, PTFE, PEEK), and leak testing
Experience with water purification technologies (deionization, ultrafiltration, reverse osmosis) and post-production gas purification
Multi-physics and CFD simulation experience (ANSYS Fluent, COMSOL, or similar)
Familiarity with electrical safety standards relevant to HV systems: UL 508A (industrial control panels), IEC 60204, NFPA 70E
Experience with PLM systems for BOM and drawing management Skills and Requirements 4-5 Years' relevant industry experience
Hardware manufacturing (Target: automotive, chemical engineering, oil & gas) + high voltage, high pressure applications
Go-to-market 0 -> 1 (manufacturing to deploying products and systems)




2D/3D Drawings in CAD/SolidWorks
GREAT COMMS B.S. in Mechanical Engineering or equivalent; 6+ years of relevant experience in commercial product design and development
First-principles understanding of statics, mechanics, materials science, heat transfer, thermodynamics, and fluid dynamics - with the ability to apply these rapidly in hand calculations
Extensive experience taking mechanical designs from concept through production, including prototype builds and manufacturing release
Proven experience in DFM/DFA - working hand-in-hand with manufacturing partners to optimize designs for producibility, assembly, and reliability
Demonstrated experience packaging and integrating electromechanical systems involving both HV and LV electrical components
Proficiency in 3D CAD (SolidWorks strongly preferred) and Thermal & Structural FEA tools
Solid hands-on aptitude - comfortable in the lab, on the shop floor, and at the test rig
Experience creating GD&T-compliant; 2D fabrication drawings (ASME Y14.5)
Familiar with UL/IEC standards
Advanced degree (M.S. or Ph.D.) in Mechanical Engineering or closely related field
Experience with PEM electrolysis, fuel cell systems, or related electrochemical systems
Hands-on experience with hydrogen, oxygen, nitrogen, or other high-purity gas systems - including pressure management, material selection (316L SS, PTFE, PEEK), and leak testing
Experience with water purification technologies (deionization, ultrafiltration, reverse osmosis) and post-production gas purification
Multi-physics and CFD simulation experience (ANSYS Fluent, COMSOL, or similar)
Familiarity with electrical safety standards relevant to HV systems: UL 508A (industrial control panels), IEC 60204, NFPA 70E
Experience with PLM systems for BOM and drawing management We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal employment opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment without regard to race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or the recruiting process, please send a request to [email protected].

📌 INDIA - Mechanical Engineer (Hyderabad)
🏢 Insight Global
📍 Hyderabad