ENERGY
SCALE

SERVICES CONTACT

ABOUT

I'm Sean Casey, the founder and sole member of Energy Scale. As a mechanical engineer with a passion for sustainable technologies and mechanical design, I'm dedicated to providing high-quality engineering and design services tailored to your needs.

I provide guidance and services for startups and established companies within the clean energy sector, from initial research to product launch. With unique expertise in electrochemical product design and development, I offer comprehensive support throughout the entire product lifecycle—ideation, prototyping, production, and commercialization. Let's collaborate to drive your sustainable innovation forward.

CONTACT
R&D SERVICES
  • - Conceptualization and ideation
  • - System modeling and optimization
  • - Analysis and simulation
  • - Design of experiments
  • - Data analysis and automation
PRODUCT DEVELOPMENT
  • - 3D CAD Design and Drafting (Autodesk Inventor)
  • - Design analysis and simulation (FEA and CFD)
  • - GD&T tolerancing (ASME Y14.5)
  • - Injection molding design
  • - Manufacturing design optimization
  • - Jig and fixture design for manufacturing
  • - Failure analysis and root cause determination
  • - Cost reduction strategies
ELECTROCHEMICAL EXPERTISE
  • - Reactor and balance of plant design
  • - Process component sizing and selection
  • - Piping and instrumentation design
  • - Sensor integration and selection
  • - Test stand design and implementation
  • - Material compatibility testing
  • - Certification assistance (UL 9540 & UL 1973)




EXPERIENCED

With over 10 years of industry experience, I drive projects to completion on time and within budget. I played a pivotal role in the development of the all-iron redox flow battery systems at ESS (NYSE: GWH), helping the organization scale from a startup to a publicly traded company. As an inventor on over seven patents, I am now dedicated to helping other companies scale their innovations.

RESPONSIVE AND ADAPTABLE

I am used to a fast-paced, dynamic work environment and can adapt to your needs quickly. With responsive communication I can collaborate with your team in an efficient manner. Drawing on my years of industry experience helps me provide proactive advice to avoid costly time delays.

EXPERT DOMAIN KNOWLEDGE

I have experience designing parts for all varieties of manufacturing techniques including injection molding, sheet metal, 3D printing, CNC, and die-cast parts. With a deep understanding of electrochemical systems, I can help turn R&D concepts into commercial products.

SERVICES

Providing a range of services at all levels of the product lifecycle from ideation to commercialization.

CONSULTING

A senior level mechanical engineer with 10+ years of industry experience and product development know-how for your company.

CAD DESIGN AND DRAFTING

Turning paper sketches into 3D models and drawings using Autodesk Inventor CAD system.

PRODUCT DESIGN AND DEVELOPMENT

Converting concept designs into commercialized products optimized for cost-efficiency and manufacturing utilizing FEA simulation and thorough analysis.

ELECTROCHEMICAL SYSTEMS

Electrochemical system design from high-level system trade-off studies to detailed reactor and balance of plant design. Test stand design including sensor integration and data acquisition and control.

FAILURE ANALYSIS

Thorough root cause determination with corrective action recommendations. I can provide strategies to find root cause quickly.

DATA ANALYSIS AND AUTOMATION

Distilling large data sets into easily understandable, actionable results using a variety of tools from Python and Jupyter Notebooks to Excel.

CONTACT

Reach out to see how we can collaborate and drive your projects forward.

I am dedicated to leveraging my experience to empower startups and established companies in the clean energy sector. Whether you're navigating the complexities of research, prototyping, or commercialization, I'm here to provide tailored solutions and support.