Mechanical Design Engineer

Job Title: Mechanical Design Engineer – Graphite

Job Description

This role provides mechanical engineering support for the design and development of high‑reliability mechanical systems, components, and structures made from graphite. You will focus on high‑heat and high‑reliability applications such as heat exchangers, power generation systems, and other advanced thermal and mechanical systems. The position spans the full product development lifecycle, from concept development and analysis through prototyping, testing, production, and commissioning, with a strong emphasis on safety, regulatory compliance, and robust materials engineering for graphite.

Responsibilities

• Develop mechanical and physical concepts and support the development of processes to create or identify structures, systems, and components for use in high‑reliability products or facilities with a strong focus on safety.
• Identify, collect, and document applicable requirements, interfaces, design bases, and design criteria by coordinating with key stakeholders and systems engineers, and support the identification of applicable industry codes and standards under the direction of project leads and systems engineers.
• Plan and perform analyses to assess structural, thermal, hydraulic, and other aspects of mechanical systems and structures to ensure they can perform their intended functions and meet all technical specifications and design requirements.
• Perform engineering computations using hand calculations and analytical tools for structural, thermal, hydraulic, and other scoping calculations as required, ensuring systems meet technical and performance requirements.
• Develop innovative mechanical solutions to refine and deploy concepts, technologies, and designs associated with mechanical systems, including pressure vessels and piping, electromechanical systems and sensors, mechatronics and automation systems, and systems using exotic and high‑temperature materials such as graphite and advanced alloys.
• Integrate design activities across engineering team members, partners, and suppliers, and perform supporting scoping and sizing calculations to down‑select design features to meet design requirements using guidance from consensus codes and standards.
• Create, update, and maintain CAD‑generated engineering models and associated documentation throughout the product lifecycle.
• Support the assessment of mechanical systems for manufacturability, assembly, and integration, providing input to ensure designs can be efficiently fabricated, assembled, and tested in a production environment.
• Write and develop design documentation, including design basis documents, technical reports, calculations, and engineering drawings, in accordance with applicable procedures and quality standards.
• Develop Verification and Validation (V&V) plans for analytical tools and support the qualification of the engineering toolset used for analysis and design.
• Perform work in accordance with established quality procedures for design and configuration management to ensure project quality and configuration control requirements are met.
• Provide independent reviews and acceptance reviews of engineering deliverables and data to verify technical accuracy, completeness, and compliance with requirements and standards.
• Maintain a professional demeanor and behavior in all forms of communication and collaboration with internal and external stakeholders.
• Collaborate closely with cross‑functional teams to ensure that graphite components and systems meet performance, reliability, and safety objectives throughout development and into production.
• Support prototyping, testing, and commissioning activities for graphite‑based systems and components, including oversight of hardware manufacturing and testing as needed.

Essential Skills

• Bachelor’s degree in mechanical engineering or a related discipline such as aerospace, nuclear, or chemical engineering from an accredited institution.
• 5–10 years of experience in mechanical engineering, mechanical design, or closely related fields.
• Hands‑on experience with actual hardware and working through the product development lifecycle through to production or fabrication, with Technology Readiness Level (TRL) at 5 or beyond and Manufacturing Readiness Level (MRL) at approximately 5 or 6 or higher.
• Experience in highly regulated industries such as aerospace, medical devices, automotive, propulsion or rocketry, defense electronics, or other similar regulated sectors.
• Demonstrated experience designing systems that incorporate graphite components, including understanding and applying the limitations and applications of graphite materials.
• Knowledge of designing and developing systems with graphite components, including understanding types of graphite, customization and manipulation of graphite through layering and crystallization, and optimizing heat transfer and structural stability.
• Experience designing and developing complex mechanical or fluid systems, assemblies, or components for high‑reliability applications.
• At least two years of demonstrated experience developing and delivering hardware or manufacturing processes in a production environment.
• Proven hardware ownership experience, including oversight of manufacturing and testing activities.
• Proficiency in engineering hand calculations for structural, thermal, hydraulic, and other relevant analyses.
• Experience using Computer‑Aided Design (CAD) and Product Lifecycle Management (PLM) software such as UG/NX, SolidWorks, CREO/Pro‑Engineer, Teamcenter, Windchill, or similar tools.
• Ability to apply materials engineering principles to graphite and other high‑temperature or exotic materials in mechanical designs.
• Strong mechanical engineering skills in areas such as mechanical design, mechanical engineering analysis, and engineering management of complex systems.
• Ability to work with and interpret industry codes and standards as guided by project leads and systems engineers.
• Strong written communication skills for preparing technical reports, calculations, design basis documents, and engineering drawings.

Additional Skills & Qualifications

• Experience with nuclear applications, including mechanical systems used in nuclear facilities or advanced nuclear technologies.
• Experience with design, qualification, licensing, and construction to the Boiler & Pressure Vessel Code (BPVC) Section III and/or Section VIII.
• Experience with regulatory frameworks such as NRC regulations and licensing for safety‑related systems.
• Experience designing systems using BPV Code, B31.1, B31.3, and other relevant industry standards.
• Experience with mechanical process equipment selection, sizing, and specification, including piping, ducting, HVAC, fire suppression systems, pumps, pressure vessels, valves, and structural supports.
• Hands‑on experience with graphite or other non‑metallic components, including fabrication, assembly sequencing, and tooling development.
• Experience in heat transfer, heat exchangers, and thermal systems, particularly in high‑heat or high‑reliability applications.
• Experience with high‑pressure vessels, fluid systems, reactors, boilers, gas turbines, combustion systems, rocket propulsion systems, steam‑driven systems, and advanced mechanical systems.
• Familiarity with crystallography and graphite structures for optimizing performance in mechanical and thermal systems.
• Experience working with mechatronics and automation systems, including electromechanical systems and sensors.
• Ability to integrate designs across multi‑disciplinary engineering teams and external partners or suppliers.
• Interest in contributing to clean energy systems development in a growing organization with significant long‑term investment.

Work Environment

The role is based in an office environment, working closely with engineering teams and cross‑functional partners. You will use modern CAD and PLM tools such as UG/NX, SolidWorks, CREO/Pro‑Engineer, Teamcenter, Windchill, or similar software to create and manage engineering models and documentation. Work involves frequent collaboration with stakeholders, systems engineers, project leads, and suppliers, as well as coordination with manufacturing and testing teams to support hardware development and production. The organization is focused on cutting‑edge clean energy systems development and is experiencing significant growth, supported by substantial external investment and expansion plans over the next several years, offering opportunities to contribute to innovative, high‑impact projects in a professional and technically rigorous setting

This is a Contract to Hire position based out of Rockville, MD.

The pay range for this position is $60.00 - $85.00/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:
• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

This is a fully onsite position in Rockville,MD.

This position is anticipated to close on May 15, 2026.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I is embedded into our culture through:

• Hiring diverse talent
• Maintaining an inclusive environment through persistent self-reflection
• Building a culture of care, engagement, and recognition with clear outcomes
• Ensuring growth opportunities for our people

Actalent is an equal opportunity employer.

About Actalent

Actalent is a global leader in engineering and sciences services. For more than 40 years, we’ve helped visionary companies advance their goals. Headquartered in the United States, our teams span 150 offices across North America, EMEA, and APAC—with four delivery centers in India led by 1,000+ extraordinary employees who connect their passion with purpose every day.

Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.