Senior Mechanical / Structural Engineer – Rotor Dynamics & Flywheel Systems

Position Overview

We are seeking an experienced Senior Mechanical or Structural Engineer with deep expertise in rotor dynamics, electric motors, turbomachinery, and high-speed rotating systems. The successful candidate will play a key role in the design, analysis, and integration of a next-generation flywheel energy storage or reaction wheel system, including the rotor, shaft, bearings, housing, and gimbal structures.

This role requires a solid understanding of mechanical design principles, structural analysis, dynamic balancing, and material behavior at ultra-high rotational speeds. The candidate will collaborate with electrical, controls, and thermal engineers to deliver a robust, efficient, and safe high-speed rotating system.

Key Responsibilities

● Lead the mechanical design and structural integrity analysis of the flywheel assembly, including rotor, shaft, containment housing, and support structures.

● Perform detailed rotor dynamic analysis— including critical speed prediction, mode shape evaluation, unbalance response, and damping assessment.

● Conduct bearing selection and sizing (magnetic, foil, or hybrid bearings) for ultra-high-speed rotors considering load, stiffness, thermal effects, and life cycle.

● Develop the gimbal and suspension systems for attitude control or vibration isolation.

● Execute finite element analysis (FEA) for static, modal, thermal, and fatigue performance of critical components.

● Ensure the containment housing meets safety margins for burst speed and energy dissipation per relevant standards.

● Support balancing, alignment, and spin testing of prototypes, including instrumentation setup for vibration and temperature monitoring.

● Interface with suppliers on materials, bearings, and fabrication of precision rotating components.

● Work closely with controls and electrical engineers on integration of sensors, actuators, and system-level design.

● Author design documentation, analysis reports, and participate in design reviews and safety assessments.

Qualifications

● Required:

● B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.

● 7+ years of experience in rotor dynamics, turbomachinery, or high-speed rotating systems.

● Demonstrated experience with rotor dynamic modeling tools (e.g., DyRoBeS, XLTRC2, MADYN 2000, or equivalent).

● Strong proficiency in FEA tools such as ANSYS, Abaqus, or Nastran.

● Hands-on experience with bearing systems (rolling element, air, magnetic, or fluid film).

● Understanding of material selection for high-speed rotors (e.g., Inconel, maraging steel, CFRP).

● Solid understanding of material fatigue, stress, and life.

● Knowledge of balancing standards (ISO 1940, API 617) and vibration analysis.

● Experience with CAD tools (SolidWorks, Siemens NX, or CATIA).

● Strong analytical, documentation, and presentation skills.

● Preferred:

● Experience with flywheel energy storage, reaction wheels, or electric motor rotors.

● Background in turbomachinery, compressors, or rotating test rigs.

● Familiarity with vacuum chamber systems, magnetic bearings, and cryogenic or thermal management.

● Experience in system integration and qualification testing for aerospace or defense applications.

● Familiarity with safety standards and burst containment testing.

Soft Skills

● Highly collaborative, cross-disciplinary mindset.

● Self-driven and detail-oriented, with strong problem-solving skills.

● Ability to work under tight deadlines and has startup mentality.

● Excellent verbal and written communication.

Job Type: Contract

Pay: $91,577.35 - $110,286.70 per year

Work Location: Remote