Sean_Casey

Experience

• Mechanical Engineer / Owner Energy Scale, LLC · Self-employed Feb 2023 – Present 2 yrs Oregon City, OR, United States ● Engineering and design services tailored to the clean tech sector
  ● Scale technologies from prototype to commercialization
  ● Reduce BOM cost by redesigning parts for high-volume production
  ● Analyze complex mechanical, fluid, and electrochemical systems using FEA, CFD, Design, and Analysis
• Principal Mechanical Engineer ESS Tech, Inc. · Full-time Aug 2022 – Dec 2023 1 yrs 4 mos Wilsonville, OR, United States ● Developed next generation designs for the all-iron redox flow battery.
  ● Modeled different battery architectures presenting trade-off studies of cost vs. performance gains.
  ● Prototyped various cost-reduced cell stack manufacturing technologies performing material testing of critical assembly joint areas.
  ● Proposed several high-value projects for the technology roadmap.
• Lead Mechanical Engineer ESS Tech, Inc. · Full-time Jan 2020 – Aug 2022 2 yrs 7 mos Wilsonville, OR, United States ● Increased battery form factor by six-fold, increasing energy and power density while simplifying manufacturing.
  ● Lead a product development team of engineers and technicians to bring the next generation cell stack from prototype to production.
  ● Developed manufacturing processes and work-instructions for next generation products as part of a cross-functional team of engineers and manufacturing technicians.
  ● Found root cause and corrective actions for a multitude of scale-up issues allowing a successful product launch.
• Senior Mechanical Engineer ESS Tech, Inc. · Full-time Oct 2016 – Jan 2020 3 yrs 3 mos Wilsonville, OR, United States ● Lead a cross-functional team of mechanical, electrical, chemical, and software engineers in the design of an updated, cost-reduced, containerized iron flow battery system.
  ● Scaled the organization by contributing to the development of the engineering change order (ECO) and engineering data management systems.
  ● Redesigned the flow cell battery stack to incorporate significant cost reductions transitioning metal machined parts to weldments and replacing o-ring seals with epoxy bonded joints.
  ● Lead root cause and corrective action initiatives on the manufacturing floor, leading a group of manufacturing engineers and technicians in the development of standard process documentation and reporting.
  ● Conceptualized larger format battery designs with trade-off studies for shunt currents, pressure drops, storage, and power.
  ● Gathered design consensus for next generation battery module with executives and engineers.
  ● Designed and prototyped early prototypes of the full-scale cell stack battery product bringing a six-fold increase in battery module size.
• Associate Mechanical Engineer ESS Tech, Inc. · Full-time Jul 2013 – Nov 2015 2 yrs 4 mos Wilsonville, OR, United States ● Developed new cell designs bringing the redox flow battery cell stack from the laboratory to prototype production scale.
  ● Increased battery scale from single cell to multi-cell, fulfilling DOE ARPA-E grants.
  ● Designed prototype battery test stand and equipment, allowing the first prototype production scale testing of the iron redox flow battery.
  ● Part of a cross-functional design team delivering the first:
  Multi-stack redox flow battery system to be tested further fulfilling DOE ARPA-E grants; commercial iron flow battery system delivered to a customer.