Staff Engineer – Stack Integration

Job Description:

Key Responsibilities

• Lead the integration of multi-layer electrolyzer stack components (MEA, PTL, gaskets, bipolar plates) to ensure proper fit, function, and performance.
• Define and optimize stack compression strategy, including compression windows, tolerances, and assembly sequences.
• Analyse and control load transfer mechanisms across layers under hydraulic pressing and bolt torquing conditions.
• Ensure uniform contact pressure distribution to balance sealing integrity, electrical contact resistance, and component durability.
• Evaluate mechanical behaviour of layers (elastic/plastic deformation, creep, stress relaxation) under assembly and operating conditions.
• Improve pressure handling capability of the stack, including resistance to leakage, deformation, and mechanical failure.
• Correlate mechanical compression with electrochemical performance (efficiency, voltage losses, degradation).
• Develop and use FEA models to predict stress, strain, and contact pressure distribution across the stack.
• Design and execute validation tests (compression mapping, torque-tension, leak and pressure cycling tests).
• Collaborate cross-functionally to ensure design robustness, manufacturability, and scalability of stack integration solutions.

Required Qualifications

• B.E or M.E in Mechanical or Chemical or Material science background
• 5 to 10 years of experience required in Electrolyzer, fuel cell, or similar electrochemical stack systems or EV systems
• Mechanical integration of multi-layer assemblies.
• Strong understanding of:
  • Stack compression mechanics
  • Load transfer through layered structures
  • Torque-preload relationships in bolted joints
• Experience with:
  • Hydraulic press assembly processes
  • Gasket sealing mechanics and material behaviour
  • Porous transport layer (PTL) compression characteristics
• Ability to interpret:
• Stress-strain curves
• Contact mechanics
• Nonlinear material behaviour. We are seeking a highly skilled Senior Stack Integration Engineer to lead the integration and optimization of electrolyzer stack architectures. This role focuses on ensuring robust mechanical, electrochemical, and pressure-performance integration across stack layers to achieve superior durability, efficiency, and operability.