Senior Mechanical Design Engineer

Role Summary:  

We are seeking a skilled Senior Mechanical Design Engineer to join our team and contribute to the development of power electronics products. The primary function of this position is to design custom machinery and support the entire project cycle from concept development through installation, commissioning, and handover to the operations team. You will work closely with cross-functional teams, including product design, Controls, manufacturing, and test engineers, to ensure efficient performance and reliability in high-power density environments. 

Responsibilities: 

•  Utilize CAD software CAD software (3D EXPERIENCE (3DX), CATIA, NX, SolidWorks, Creo etc.) to create detailed mechanical designs. 

• Model and design complex electro-mechanical parts, including plastics, sheet metal, insulators, magnetic components, and high-voltage connectors. 

• Perform mechanical design analysis, including structural FEA, thermal CFD, vibration, and fatigue assessments. 

• Solve packaging challenges involving electrical isolation, sealing, thermal dissipation, EMI/EMC shielding, and mechanical shock/vibration. 

• Define and execute validation test plans including structural, thermal, and environmental testing. 

•  2D drawings with GD&T for production and inspection. 

• Create engineering documentation, tolerance stacks, BOMs, and release packages through PLM systems. 

• Collaborate cross-functionally with electrical, thermal, Firmware and controls, manufacturing, test, and industrial design teams. 

• Work closely with suppliers to optimize DFM, DFA, and tooling strategies for high-volume production. 

• Lead prototype development, fabrication, assembly, and mechanical testing of new designs. 

• Support root-cause analysis of design issues in pilot or production builds and lead iterative improvements. 

• Drive trade studies to inform system-level decisions on design architecture, materials, and manufacturing processes. 

• Guide selection for structural, thermal, and electrical compatibility in high-voltage environments. 

• Contribute to the layout and design of integrated cooling systems including cold plates, thermal interfaces, and airflow paths. 

• Develop assembly procedures and manufacturing instructions to support scalable production. 

• Participate in mechanical  FMEA and DVP&R activities across product lifecycle stages. 

• Work with quality and reliability teams to meet performance, lifecycle, and safety targets. 

Qualifications: 

• Bachelor’s or Master’s degree in Mechanical Engineering or a related field. 

• 3+ years of experience in mechanical design for power electronics, automotive, industrial, or energy products. 

• Expertise in CAD modeling using 3D EXPERIENCE (CATIA V6/V5), SolidWorks, NX, or Creo. 

• Deep understanding of mechanical fundamentals—statics, dynamics, heat transfer, and materials. 

• Proficiency in GD&T, tolerance analysis, and DFM/DFA principles. 

• Experience designing enclosures for IP-rated or outdoor-rated power equipment. 

• Experience with high-volume manufacturing processes such as injection molding, die casting, extrusion, and sheet metal forming. 

• Working knowledge of materials: metals (aluminum, steel), plastics, ceramics, gaskets, potting compounds. 

• Hands-on experience taking designs from prototype through production deployment. 

• Familiarity with PLM systems (3D EXPERIENCE, Windchill, etc.) and engineering change workflows. 

• Comfortable with root-cause analysis, failure mode resolution, and mechanical reliability testing. 

• Strong communication skills and ability to lead cross-functional design reviews and technical deep-dives. 

• Prior experience collaborating with suppliers on tooling development, DFM feedback, and tolerance negotiations. 

• Familiarity with PCBAs, connectors, and mechanical integration of high-density electronic assemblies. 

• Experience with design and test documentation for regulatory standards (UL, IEC, NEC preferred). 

• Passion for product innovation, sustainability, and enabling electrification through engineering excellence. 

• Willingness and ability to travel up to 15% - 20% including internationally 

Bonus Qualifications: 

• Strong background in structural, thermal, and vibration analysis using tools like Ansys Mechanical, Fluent, and Maxwell. 

• Familiarity with electronics packaging and PCB interface considerations. 

• Experience with medium- to high-voltage systems and insulation coordination (creepage, clearance, potting, sealing). 

• Experience working in Agile development environments, including task management and sprint planning using Scrum methodologies and tools like Jira.  

Please note: This role requires working on-site 5 days a week. We do not offer hybrid or remote options.