Mechanical Design Engineer - Cell & Stack Development

at Hysata Pty. Ltd. (View all Jobs)

Port Kembla, New South Wales, Australia


About us

Hysata is on a mission to accelerate the shift from fossil fuels to green hydrogen with the world’s most efficient electrolyser. Our breakthrough capillary-fed electrolyser achieves an unprecedented 95% system efficiency (41.5 kWh/kg) – a step change from incumbent technologies, which typically sit at ~75% and already ahead of International Renewable Energy Agency’s 2050 target. This leap in performance enables a radically simpler system design, slashing both energy use (opex) and system and renewables capex.

Hysata’s innovation has captured global attention, including publication in Nature Communications and support from leading strategic and financial investors such as BP, POSCO and Vestas. With over 100 team members, we’re a high-performing, purpose-driven company, proud to be 35% women, representing 20+ nationalities, and united by a shared mission to enable the decarbonisation of hard-to-abate sectors such as steel, chemical manufacturing, shipping and aviation.

Having secured Australia’s largest ever cleantech Series B raise of US$111 million, Hysata is scaling rapidly to bring our technology to market. With strong customer demand and a clear path to manufacturing at scale, we are on track to become a global leader in green hydrogen and put a major dent in global emissions.

About the role

We are seeking a high-performing Mechanical Design Engineer to develop polymer components within our hydrogen electrolyser cell and stack.

You will design, analyse, prototype and industrialise precision components operating in demanding electrochemical and fluid environments. Your work will directly influence system efficiency, reliability, manufacturability and cost. This is a hands-on, high-accountability role suited to engineers who thrive on solving complex physical problems and delivering prototype hardware into production. You will thrive in the fast-paced start-up world where no two days are the same. You’ll be joining a team of smart, driven, collaborative and highly dedicated individuals who love solving engineering challenges and who are excited to be fighting the climate crisis.

Role responsibilities

Component Ownership & Design

  • Own components from concept through validation and production release to meet project deadlines;
  • Create detailed 3D models and 2D drawings in NX and manage releases via Teamcenter PLM;
  • Perform tolerance stack-ups and ensure robust mechanical integration;
  • Design injection molded polymer parts for manufacture, assembly and cost, supporting scale-up to production; and
  • Contribute to DFMEA, risk assessments and verification & validation planning.

Prototyping, Testing & Manufacturing

  • Build and test prototype hardware to validate design intent;
  • Work with our testing team to define test plans, analyse data, diagnose failure modes and iterate design improvements rapidly;
  • Engage suppliers on manufacturing processes, tolerances and quality metrics; and
  • Support transition from prototype to scaled production.

Collaboration

  • Lead and participate in design reviews and technical workshops;
  • Work closely with other engineers and stakeholders to ensure alignment on project goals and requirements;
  • Communicate complex technical concepts clearly across engineering and non-technical teams; and
  • Operate effectively in a fast-paced, evolving hardware development environment.

What you'll bring

  • Bachelor’s degree in Mechanical Engineering or related discipline;
  • 3–6+ years of experience delivering mechanical components into prototype and/or production environments;
  • Strong proficiency in NX, SolidWorks or equivalent 3D CAD software;
  • Experience with tolerance analysis, structural or fluid calculations, and failure investigations;
  • Familiarity with requirements capture, DFMEA and structured Verification and Validation (V&V) processes;
  • Hands-on prototyping and workshop experience.

Experience in one or more of the following is advantageous

  • Injection-moulded polymer components;
  • Elastomeric sealing systems;
  • Microfluidics or precision assemblies;
  • Pressurised fluid or electrochemical systems;
  • Alkaline Electrolyser compatible or corrosion-resistant materials.

What we offer

Perks Include (but are not limited to):

  • Idyllic Beachside Location;
  • Stock options;
  • Salary Sacrifice into Superannuation;
  • Flexible working conditions;
  • Recognition of Service;
  • Wellness Allowance;
  • EAP through Sonder;
  • Novated Leasing;
  • Employee Discount Program through Flare; and
  • Awesome work environment and team!

 

If you don’t tick every box in this ad, please don’t rule yourself out just yet. We’ve seen the research that people from underrepresented backgrounds tend to only apply when the checklist is all ticks. We take pride in inclusion and hiring incredible human beings with great potential over ticking boxes – so if this role resonates with you, apply below!

No agency contact please.