Electrolyzer Engineer Jobs in Wisconsin (NOW HIRING)

Status: Full-Time, Salaried, Exempt
Reports to: Director of Electrolyzer Technology
Position Summary: The Materials Development Engineer is responsible for developing high temperature films, coatings, seals, and production methods for our SymbionTM intermediate-temperature steam electrolyte platform. This role bridges fundamental materials science and electrolyte system integration, ensuring that ceramics, seals and advanced coating perform reliably in a stressful environment with hydrogen and oxygen produced on opposing sides of the cell. You will own materials development across the electrolyzer stack, working directly with electrolyzer technology leadership and cross-functional engineering teams to translate laboratory innovations into scalable, production-ready solutions.
Expected Hours of Work: This is a full-time position. Advanced Ionics office hours are 6:30am - 6:30pm, with core hours being 8am - 4pm Monday through Friday. Your work schedule will generally be within normal business hours. Occasionally, there will be requests to work outside of normal business hours for special events. In those instances, a notice will be sent as early as possible. Occasional evenings and weekends may be required.
Essential Functions of the Position:

• Design and develop advanced materials for multiple portions of our electrolyzer cell, balancing mechanical strength, thermal stability, electrochemical performance, and manufacturing scalability.
• Optimize materials-electrolyte compatibility in working environments; evaluate capillary behavior, wetting properties, and corrosion resistance under thermal cycling and conditions.
• Develop production methods and processes of various electrolyzer materials.
• Conduct simulations and testing to evaluate the performance of materials and processing methods under various operating conditions.
• Drive electrochemical materials integration, collaborating with electrochemist and stack engineering teams to ensure materials contribute to the target performance metrics.
• Work with suppliers to source, qualify and optimize raw materials, precursors, and specialized equipment; negotiate technical specifications and pilot production runs.
• Develop and maintain comprehensive documentation, including the materials specifications, processing SOPs, failure analysis reports, and IP disclosures related to seals, coatings, and ceramic compositions.
• Participate in cross-functional teams to ensure that component designs are integrated effectively with cell architecture, stack sealing strategy and system level performance targets.
• Contribute to technology strategy for advanced materials in intermediate-temperature electrolysis, including evaluation of emerging ceramics, glasses, high-temperature polymers, and unconventional processing methods.

Physical Requirements:

• Ability to lift, carry and move equipment up to 50 pounds, frequently
• Ability to stand, walk, bend, stoop and reach for extended periods
• Ability to climb ladders and stairs as needed
• Manual dexterity required for operating warehouse tools and equipment
• Ability to work in varying temperatures (hot/cold) within the warehouse environment
• Visual and auditory ability to safely operate equipment and identify hazards

About Advanced Ionics:
Our mission is to decarbonize the "hard-to-abate" heavy industrial sectors of the world economy with a new class of electrolyzers. Advanced Ionics is seeking a highly motivated people to join our growing team that is dedicated to developing transformational "green hydrogen" industrial electrolyzer systems.
At Advanced Ionics, we've created a green hydrogen platform that allows industrial hydrogen producers and users to achieve sustainability and decarbonize, without sacrificing profit. We combine our patented Symbiotic electrolyzer technology with our customers' onsite process and waste heat to produce the lowest-cost green hydrogen on the market.
We're a thoughtful, venture-backed, and mission-oriented team of engineers, creatives, and business people looking to change the world. And, we're proud to say we're headquartered in the great city of Milwaukee, in the heart of the industrial Midwest.
Consistent with our commitment to diversity & inclusion, we value people with the ability to work on diverse teams and with a diverse range of people. We especially encourage members of traditionally underrepresented communities to apply, including women, people of color, LGBTQ people, veterans, and people with disabilities.
What We Offer:

• This is a full-time position
• Competitive, negotiable salary
• Vesting options for equity in a venture-backed, climate-tech startup
• Health and retirement benefits, with flexible options
• Generous vacation policy
• Paid parental and sick leave

About Our Hiring Process:
Our hiring process consists of the following:

• Phone Screen
• 1st Round Virtual Interview
• 2nd Round (ideally) In-Person Interview
• References/Background
• Conditional Job Offer

Professional Qualifications:

• Bachelor's degree in Materials Science, Ceramic Engineering, Chemical Engineering or equivalents.
• Master's degree is strongly preferred but not required if equivalent industry experience is demonstrated.
• At least 5 years of experience in designing, developing and quantifying ceramic materials and seals for complex systems, preferably in the high temperature electrolyzer, fuel cell, or adjacent industries.
• Strong foundation knowledge of ceramic materials science:
  • Phase diagram, sintering mechanism, thermal expansion, and mechanical properties (flexural strength, fracture toughness and creep resistance).
  • Glass and glass-ceramic compositions for seal applications.
  • Microstructure-property relationships; ability to interpret SEM, XRD, and thermal analysis data.
• Ability to demonstrate expertise in high temperature seals, including wet seal design, sealing materials (glasses, ceramics, micas, vermiculites, and high temperature polymers) and seal performance metrics (leak rate, compression set, thermal cycling durability).
• Proficiency in simulation and testing methodologies:
  • Thermal analysis (DSC, TGA, dilatometry).
  • Mechanical testing (compression, flexure, thermal shock resistance).
  • Electrochemical testing (if experience available) or willingness to rapidly develop competency.
• Hands-on experience with advanced ceramic processing (tape casting, slip casting, hot-press sintering, or wet coating methods); understanding of scaling challenges (shrinkage, defect propagation, process control).
• Ability to execute design of experiments (DOE) protocols with robust statistics-backed methods (preferred).
• Data science and/or data management experience in a professional setting preferred