Senior Mechanical & Manufacturing Engineer

About us

PlasmaLeap Technologies is a globally recognised Australian clean-chemicals company reinventing how the world makes molecules. We’re decarbonising heavy industry by putting clean, distributed chemical production in the hands of communities themselves. Our proprietary plasma reactors use renewable electricity, air and water to produce green fertilisers and fuels, creating a scalable, commercially viable pathway to net-zero that strengthens food security and bypasses fragile, fossil-fuel global supply chains entirely. 

If you want to build deep tech that solves climate and food security in the same breath, and you want to do it at speed, with urgency, with purpose, and with people who are actually executing not just talking about it, then you’ll fit right in. 

The opportunity

We are looking for a Senior Mechanical & Manufacturing Engineer (DFM/Industrialisation, Thermal, Prototyping) to own the mechanical design and industrialisation of high-power electromechanical systems, taking products from early concept through production release and reliable scaling. Operate as a senior individual contributor with high ownership across architecture, DFM/DFA, suppliers, and thermal performance.

What you’ll do

Product life cycle ownership (mech + electromechanical)

• Take electromechanical products (mechanical + electronics, high power systems) through the full product life cycle: concept → prototype → iterate → DFM → DVT → production release → manufacturing support → sustaining engineering
• Drive clear mechanical requirements and interfaces across modules, racks, and container systems
• Own mechanical architecture, packaging strategy, and serviceability approach (assembly, access, field repair)
• Lead mechanical design reviews and part release process

Design for Manufacture & industrialisation

• Lead DFM/DFA from day one: part consolidation, tolerance stack-ups, fastener strategy, assembly sequencing, test access, and work instructions
• Own supplier engagement: design reviews with manufacturers, quotes, lead-times, alternative processes/materials, and production readiness
• Set up scalable production documentation: drawings, BOM hygiene, revision control, inspection criteria, critical-to-quality features

High-volume manufacturing processes

• Design for and collaborate on prototype/production using:

– Die casting

– Injection moulding

– Other scalable processes (sheet metal, CNC, extrusions, stamping, coatings, sealing/gasketing, etc.)

• Recommend the right process per part based on cost, schedule, tolerances, reliability, and supply chain

Thermal engineering (CFD + real-world validation)

• Managing complex thermal problems for high power systems using CFD + lab testing
• Design and validate thermal paths: heatsinks, cold plates, airflow design, ducting, fans, heat exchangers, thermal interfaces, sensor placement
• Build a repeatable thermal test workflow: instrumentation plans, acceptance tests, correlation between CFD and measured results

Prototyping & lab build support (hands-on)

• Be hands-on: design prototypes and actively support the team building them in the lab
• Rapidly iterate CAD, drawings, and parts based on test outcomes
• Create fixtures/jigs as needed to accelerate learning and improve build quality

What we’re looking for (must-haves)

• Strong track record taking electromechanical products (mechanical + electronics; ideally high power, larger-format products) through full product life cycle into production
• Deep Design for Manufacture experience (DFM/DFA),
• Experience working with both startup pace and large-scale manufacturing environments (or strong evidence you can bridge both)
• Strong CAD skills (parts, assemblies, drawings, configurations; ideally PDM discipline)
• Demonstrated experience with die casting and injection moulding, including design rules, tooling considerations,and supplier collaboration
• Proven thermal problem-solving capability: CFD + real-world testing and correlation
• Industrial or outdoor electromechanical systems, large-format packaging, and scale manufacturing environments (desired)

Why you should join PlasmaLeap Technologies:

We Move Fast - Build, test, and learn outside your comfort zone alongside curious, driven teammates. 

We Make an Impact - Work on meaningful challenges that decarbonise industry and improve global food security. 

We’re Getting Recognised - PlasmaLeap is earning global recognition through international awards and world-class investors backing us from multiple continents,

We Own It - Every team member has a voice and takes real ownership in a culture of experimentation as we rapidly develop, prototype and scale our technology.  

We Celebrate Wins - Enjoy fun, engaging company events while working hard on ambitious goals. 

We Reward Talent - To build the best, you have to employ the best. Competitive salary, equity, and coverage for training and conferences.