Engineer, Mechanical

Job Purpose

The Mechanical Engineer is responsible for end-to-end hardware ownership of components and sub-systems for the KARNO generator, taking designs from CAD through prototype, test, and validation. Working across mechanical, electrical, software, and performance teams, this role designs and troubleshoots complex thermal and mechanical systems that must perform reliably across extreme operating environments and a wide range of fuels. The position exists to advance the development of Hyliion's fuel-agnostic power generation technology through hands-on, test-driven engineering and disciplined design execution.

Duties and Responsibilities

• Own hardware components and sub-systems end-to-end—from concept through durability, manufacturability, serviceability, cost, weight, and validation—taking designs from CAD to hardware running on a test stand.
• Design components and sub-systems that must survive extreme thermal environments, perform across a wide range of fuels (20+), and push the boundaries of metal additive manufacturing.
• Create 3D models in NX and generate 2D prints with full GD&T per ASME Y14.5.
• Perform design checking and print review to ensure tolerances, processes, and material specifications align with Hyliion's GD&T standards (ASME Y14.5).
• Conduct fluid and thermal systems design and optimization.
• Perform structural and thermal FEA (ANSYS or equivalent).
• Install, calibrate, and read instrumentation for pressure, temperature, flow, strain, and acceleration in lab environments.
• Execute prototype build, test, and validation cycles early and often to identify and resolve issues in the lab rather than the field.
• Collaborate cross-functionally with design, electrical, software, and performance teams throughout the development process.
• Lead and participate in technical reviews—presenting findings, driving trade-off discussions, and owning engineering decisions.
• Support supplier identification, selection, and procurement for prototype and production hardware needs.
• Additional duties and responsibilities as assigned, needed, or required for the business.

Qualifications

Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Qualifications include:

• Education, Experience and Certifications
• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or Electrical Engineering; Master's preferred.
• 0–5 years of engineering experience with a track record of designing and troubleshooting complex systems.
• Background in automotive, aerospace, or medical device engineering is a strong plus.

• Skills and Abilities
• Expert-level NX 3D CAD proficiency, including 2D print generation with full GD&T per ASME Y14.5.
• Experience in fluid and thermal systems design and optimization.
• Structural and thermal FEA experience (ANSYS or equivalent).
• Comfort in lab environments: installing, calibrating, and reading instrumentation for pressure, temperature, flow, strain, and acceleration.
• Exposure to electrical systems (motors, inverters, batteries) is a bonus.
• Self-starter who identifies what to test next and makes it happen.
• Highly collaborative across mechanical, electrical, software, and test disciplines.
• Clear communicator who can articulate complex trade-offs to diverse stakeholders and follow through on commitments.
• Treats failed test results as data, not setbacks.

Role Classification and Working Conditions

This is a salaried, exempt-level position. This position typically works in an office environment; and given the nature of our business is also exposed to operations/warehouses/production environments.

Physical/Other Requirements

• Ability to lift and/or move up to 30 pounds.
• Ability to travel, as needed, by plane, automobile, etc. up to 10%