Mechanical Engineer I

About the Role

This entry-level engineering role supports Plug Power’s electrolyzer (ELX) and PEM fuel cell (FC) stack programs. The position combines hands-on lab work, including stack teardown, failure analysis support, test stand operation, and station support, with engineering fundamentals for designing, troubleshooting, and improving stack hardware and test methods.

Key Responsibilities

• Support ELX and FC stack failure-analysis activities: stack disassembly/teardown, inspection, root cause investigation, and sample preparation.
• Operate, troubleshoot, and support 1 kW, 9 kW, 15 kW, 50 kW, and 1 MW PEM test stands and associated data acquisition systems; provide day-to-day test station support.
• Set up and execute standard and non-standard test procedures for PEM FC and ELX components and stacks.
• Partner with engineering and lab staff to develop new lab capabilities: teardown procedures, test protocols, fixtures, tooling, and data collection/reporting methods.
• Record, organize, and analyze test and teardown data; prepare documentation, reports, and presentations.
• Support engineering design activities for stack components and test fixtures: 3D CAD modeling, drawings, and bills of materials.
• Assist with Design Failure Mode and Effect Analyses (DFMEA) and design reviews for stack hardware and test fixtures.
• Collaborate cross-functionally with manufacturing, quality, and analytical teams to resolve issues.
• Maintain lab equipment, tools, and test fixtures; support calibration, inventory management, and lab safety practices.
• Support engineering studies, investigations, and continuous improvement initiatives.
• Represent Plug Power professionally.

Requirements & Tech Stack

• BS degree in Mechanical Engineering or a related engineering field.
• 0–2 years of relevant experience; co-ops, internships, senior design projects, or academic lab work involving fuel cells, electrolyzers, electrochemistry, or hands-on mechanical testing are a strong plus.
• Exposure to PEM fuel cell or electrolyzer stack hardware, testing, or teardown/failure analysis is highly desirable but not required.
• Basic familiarity with 3D CAD modeling and drawings (Creo/Windchill a plus).
• Interest in or exposure to GD&T, FEA/CFD, and DFMEA methodology.
• Comfortable working hands-on in a lab environment with test equipment, tooling, and chemical handling.
• Strong documentation skills for recording and communicating test results.
• Proficiency with standard computer tools: Word, Excel, PowerPoint, Outlook, data logging/analysis software.
• Strong communication skills (written and verbal).
• Ability to work effectively in cross-functional teams.
• Self-motivated, detail-oriented, and eager to learn.
• Ability to work at Plug Power’s Rochester Innovation Center.
• Ability to travel for business need up to 10%.

Qualifications

This section details desirable, but not strictly required, experience and exposure.

• 0-2 years of relevant experience.
• Co-ops, internships, senior design projects, or academic lab work involving fuel cells, electrolyzers, electrochemistry, or hands-on mechanical testing.
• Exposure to PEM fuel cell or electrolyzer stack hardware, testing, or teardown/failure analysis.
• Basic familiarity with 3D CAD modeling and drawings.
• Interest in or exposure to GD&T, FEA/CFD, and DFMEA methodology.