Job Title: Mechanical Design Engineer - Graphite Systems
Job Description
This role provides mechanical engineering support for the design and development of high-reliability mechanical systems, components, and structures made from graphite materials, particularly for high-heat and advanced energy applications. You will drive concept development, perform detailed analyses, and guide designs from early feasibility through prototyping, testing, and production, ensuring all systems meet stringent technical specifications, safety expectations, and industry standards.
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 basis, and design criteria by coordinating with key stakeholders and systems engineers.
Support the identification and application of relevant industry codes and standards under the direction of project leads and systems engineers.
Plan and perform analyses to assess the ability of structures and systems to perform their intended functions and to meet technical specifications and design requirements.
Perform computations using hand calculations and analytical tools for structural, thermal, hydraulic, and other scoping calculations as required by project leads and systems engineers.
Develop innovative mechanical solutions to refine and deploy concepts, technologies, and designs for 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.
Design and develop systems that incorporate graphite components, including optimization of graphite crystalline structures for high-heat applications and heat transfer performance.
Integrate design activities across engineering team members, partners, and suppliers, and perform supporting scoping and sizing calculations to select design features that meet requirements using guidance from consensus codes and standards.
Create, update, and maintain CAD-generated engineering models and associated documentation.
Support assessments of mechanical systems for manufacturability, assembly, and integration, providing input to ensure designs are practical for production and fabrication.
Write and develop design documentation, including design basis documents, technical reports, calculations, and drawings, in accordance with applicable procedures.
Develop Verification and Validation (V&V) plans for analytical tools and support the qualification and ongoing improvement of the analytical toolset.
Perform work in accordance with quality procedures for design and configuration management to ensure project quality requirements are consistently met.
Provide independent reviews and acceptance reviews of engineering deliverables and data to support robust design verification and quality assurance.
Exercise hardware ownership, including oversight of manufacturing and testing activities, to ensure designs are realized as intended.
Collaborate closely with cross-functional teams throughout the full product development lifecycle, from concept and proto@type through to production and fabrication at higher Technology and Manufacturing Readiness Levels.
Maintain a professional demeanor and clear, respectful communication in all interactions and forms of correspondence.
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 with the full product development lifecycle through to production or fabrication, ideally at Technology Readiness Level (TRL) 5 or higher.
Experience delivering hardware or manufacturing processes in a production environment for at least two years.
Experience in a highly regulated industry such as aerospace (including commercial aviation), medical devices, automotive, propulsion/rocketry, defense electronics, or similar sectors.
Demonstrated experience designing systems that incorporate graphite components, including understanding of graphite materials, their limitations, and their applications.
Knowledge of graphite @types and the processes for customization and manipulation of graphite through layering and crystallization to optimize heat transfer and structural stability.
Proficiency with engineering hand calculations for structural, thermal, hydraulic, and related analyses.
Experience designing and developing complex mechanical or fluid systems, assemblies, or components, including high-pressure and high-temperature applications.
Proficiency with 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 develop and interpret technical documentation, including design basis documents, technical reports, calculations, and engineering drawings.
Strong analytical skills with the ability to plan and perform engineering analyses to verify performance against technical specifications and design requirements.
Ability to work within established quality procedures for design and configuration management.
Effective communication skills and the ability to collaborate with systems engineers, project leads, partners, and suppliers.
Additional Skills & Qualifications
Experience with nuclear applications, including systems used in advanced energy or power generation environments.
Experience with design, qualification, licensing, and construction to Boiler & Pressure Vessel Code (BPVC) Section III and/or Section VIII.
Familiarity with regulatory frameworks such as NRC regulations and licensing processes for safety-related systems.
Experience with design using Boiler & Pressure Vessel (BPV) Code, B31.1 or B31.3 piping codes, and other relevant industry standards.
Background in 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 methods, assembly sequencing, and tooling development.
Experience working with high-pressure vessels, fluid systems, reactors, boilers, gas turbines, combustion systems, rocket propulsion systems, heat exchangers, steam-driven systems, thermal systems, or advanced mechanism systems.
Knowledge of heat transfer, heat exchangers, and thermal system optimization, particularly in high-heat or power generation applications.
Familiarity with mechatronics, automation systems, electromechanical systems, and sensors.
Experience working with exotic and high-temperature materials beyond graphite, such as advanced metal alloys.
Demonstrated ability to integrate design work across multidisciplinary engineering teams and external partners.
Interest in or experience with clean energy systems and advanced small modular reactor technologies.
Work Environment
This position operates primarily in an office environment, working closely with a multidisciplinary engineering team focused on cutting-edge clean energy systems development. You will use modern CAD and PLM platforms such as UG/NX, SolidWorks, CREO/Pro-Engineer, Teamcenter, Windchill, or similar tools to create and manage engineering models and documentation. The role involves frequent collaboration with project leads, systems engineers, manufacturing teams, and suppliers, as well as participation in design reviews and configuration management activities. The organization is in a strong growth phase, supported by significant long-term investment and expansion plans, offering opportunities to work on innovative, high-impact projects in advanced energy and high-reliability mechanical systems.
Job Type & Location
This is a Contract to Hire position based out of Rockville, MD.
Pay and Benefits
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)
Workplace Type
This is a fully onsite position in Rockville,MD.
Application Deadline
This position is anticipated to close on May 1, 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.
