Sr. Staff Mechanical Design Engineer

Responsibilities:

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

• Lead the mechanical architecture and design of medium-voltage power electronics converter assemblies and complex electro-mechanical parts including plastics, sheet metal, insulators, magnetic components, and high-voltage connectors

• Perform 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 structural, thermal, and environmental validation test plans

• Create 2D drawings with GD&T, engineering documentation, tolerance stacks, BOMs, and release packages through PLM systems

• Collaborate with electrical, thermal, Firmware and controls, manufacturing, test, industrial design, and 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 pilot or production issues and lead iterative improvements

• Drive trade studies on design architecture, materials, and manufacturing processes

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

• Contribute to cooling system layouts 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

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

• Mentor junior engineers and provide technical leadership across product programs

• Contribute to technology development for future-generation SST products and enclosures

 Qualifications:

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

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

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

• Deep understanding of 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 injection molding, die casting, extrusion, and sheet metal forming

• Working knowledge of metals (aluminum, steel), plastics, ceramics, gaskets, and potting compounds

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

• Familiarity with PLM systems (3DEXPERIENCE, 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)

• Ability to drive concurrent engineering initiatives across product timelines

• Passion for product innovation, sustainability, and electrification

• Willingness and ability to travel 15%–20%, including internationally

Bonus Qualifications: 

• Experience working in Agile development environments using Scrum methodologies and tools like Jira

• Strong background in structural, thermal, and vibration analysis using 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)