Senior/Staff Materials Process Engineer

About Mainspring Mainspring Energy manufactures and delivers fuel-flexible, low-emissions local power solutions that rapidly add new capacity and deliver reliable, affordable, and sustainable electric power. The company began commercial shipments of its Mainspring Linear Generators in 2020 and today has hundreds of megawatts in advanced development and field operations for leading Fortune 500 companies, data centers, and utilities. Mainspring also partners with global energy leaders including AEP, NextEra Energy Resources, Schneider Electric, and more. The core values that ground our work, guide our decisions, and connect us together: Pragmatic Optimism Excellence without Ego Proactive Collaboration

We have a high-impact opportunity for a Materials and Process Engineer who wants to join a world-class engineering team and help scale production of the Linear Generator. The materials and process team at Mainspring Energy works on complex development projects which are at the intersection of properties, performance and processing of a wide range of materials – non ferrous, ferrous, coatings, graphite, polymers etc. In this role, you will develop reliable cost effective materials solutions and manage existing solutions through validation testing, process development and deployment on an actual part/subassembly. This is a great opportunity to be part of cross functional projects and collaborate with multiple teams such as Supply chain, Quality, Reliability, Design and Production.

Lead independent process development and material validation of cast metal components and other mechanical systems in the Linear Generator Collaborate with other members of the Materials and Engineering teams to characterize material properties, identify failure modes, and execute validation tests to meet reliability requirements Create, develop, and optimize material and process specifications related to castings and other mechanical components. Write specifications, process control, and quality control plans for cast and other mechanical components Collaborate with other teams such as mechanical design, supply chain and quality to qualify processes and establish key process controls at manufacturing locations, including casting suppliers Participate in FMEA for design, process, and maintenance Support the Materials and Process team with failure analysis and process development projects across multiple materials and process areas (e.g., coatings, polymers, graphite, joining/welding)

BS in Materials Science/Engineering or Mechanical Engineering MS + 5 years or PhD + 3 years of industry experience Prior experience with metal casting processes (e.g., die casting, investment casting, sand casting) and their impact on part properties and performance is strongly preferred Fundamental understanding of properties and performance of engineering materials, and basic knowledge of structure-property relationships Broader exposure to other materials and process areas — such as coatings, polymers, graphite, forging, or joining/welding — is a plus Experience with volume production of metal or cast components is highly preferred Working knowledge and experience with FMEA (Failure Mode and Effects Analysis) Demonstrated experience with statistical data analysis and reporting (Matlab/Python, Google Sheets/Excel, Weibull++, etc.) Excellent communication skills, adaptable self-starter, enjoys collaboration in a fast-paced environment

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