Staff Engineer Stack Integration

• 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
  
  

• 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

The ideal candidate will have deep expertise in load transfer mechanisms, compression behaviour, and torque-induced sealing performance, along with a strong understanding of electrochemical stack physics