Breakthrough Energy Ventures Portfolio Company Career Opportunities

Iron Flow Stack Design Engineer



Wilsonville, OR, USA · Oregon, USA
Posted on Wednesday, January 31, 2024

Catalyzing a cleaner future.

ESS is a globally recognized leader in sustainable energy storage and is consistently identified as one of the most innovative and exciting technology players in energy storage. Trading on the NYSE (GWH), it is poised to be one of the fastest growing energy technology companies in the world, with projects already across 4 continents. The ESS vision is about enabling the decarbonization of the grid by enabling us to achieve up to 100% of our electricity from clean, sustainable renewable energy.

These are ambitious goals, and we are pursuing them with passion. At ESS, we are leading the energy transition, creating the sustainable energy solutions of the future to help individuals, businesses and communities change energy into lasting value.

ESS is seeking a motivated and versatile Iron Flow Stack Design Engineer to join our team. Our current program scope involves the design, development and evaluation of a new generation power module, and electrolyte management system, to characterize and improve electrolyte chemistry.

What you’ll do at ESS.

  • Proven track record in leading stack design for high volume manufacturing and meeting the industry standards for performance, durability, and cost.
  • Based on System Electrical and Mechanical Architecture, design, test, and validate iron flow battery stacks focusing on stack materials, performance, durability and cost optimization.
  • Work with the System Integration Team on optimizing the electrical and mechanical architecture.
  • Responsible for component design: FEA of mechanical stress and deformation, fluid flow, load distribution, tolerancing, and design for manufacturability, including preparation of detailed documentation and in-depth technical review.
  • Develop functional requirements for stack components and materials.
  • Develop and design components and assemblies for Iron flow battery stacks, to meet functional requirements.
  • Order and inspect components for compliance with specifications.
  • Design compression systems for iron flow battery stacks.
  • Collaborate with manufacturing team to design for manufacturability and volume production considerations, develop inspection criteria, and evaluate component suppliers.
  • Perform engineering calculations to support design concepts, including stress analysis for mechanical robustness, CFD for uniform flow and pressure distribution, and heat transfer.
  • Lead GD&T and stack-up tolerancing calculations and optimizations.
  • Perform FMEA, and Functional Safety processes.
  • Lead activities to optimize stack performance and durability, while lowering costs for components and assembly.
  • Develop robust manufacturing processes for stack assembly using DFMA – design for manufacturing and assembly.
  • Understand, investigate, and address electrical efficiency losses in the stack.
  • Collaborate with cross-functional teams to validate new materials, optimize startup protocols, and reduce conditioning time.
  • Conduct experiments using fuel cell test stations and analytical instruments.
  • Stay informed about external fuel cell concepts and technology developments.

What you bring to the table.

Minimum Requirements:

  • Master’s degree in chemical, mechanical, electrical, or materials science engineering (or related discipline).
  • Expertise in stack design – flow batteries, fuel cells or electrolyzers.
  • Expertise with CFD, electrical, mechanical simulations software.
  • Experience with flow battery technology, especially iron-based systems.
  • Knowledge of electrochemical diagnostics (e.g., cyclic voltammetry, impedance spectroscopy).
  • Strong analytical skills and attention to detail.
  • Knowledge of redox flow batteries and their operation.
  • Knowledge of iron-based electrolytes for flow batteries.
  • Expertise with designing stacks and stack components for batteries, fuel cells or electrolyzers.
  • Expertise in mechanical, electrical, and thermal simulations.
  • Expertise in a variety of materials, including thermosetting and thermoplastics materials.
  • Expertise with manufacturing processes including molding, machining, forming, and joining methods.
  • 5 plus years of experience designing and analyzing precision components for complex assemblies.
  • Design of pressure containment devices, sealing systems, and precision components.
  • Capable of working well in a multi-disciplinary team environment with a high degree of collaboration.

Benefits of working at ESS.

In addition to the value of working with and helping grow a global reaching clean technology, ESS offers a Company assisted Health insurance, Approved PPE Reimbursement, Medical & Dental; Flex spending account; 8 paid holidays; 401K, and a competitive PTO accrual.

As an equal opportunity employer, we are open to considering every qualified candidate who is eligible and legally authorized to work in the United States on a full or part-time basis, without a need for sponsorship.

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities, and activities may change at any time with or without notice.