Senior Mechanical Engineer - Power Systems Packaging

Job Title: Senior Mechanical Engineer – Power Systems and Electronics Packaging

This role focuses on the mechanical design, packaging, and validation of advanced power electronics and energy storage systems for demanding land‑based, shipboard, airborne, and subsea environments. The Senior Mechanical Engineer will lead the 3D packaging of complex power converters and PLC systems, design thermal management solutions, perform structural and thermal analyses, and support hardware build, test, and rapid prototyping efforts. The position offers the opportunity to work on cutting‑edge wide band gap Gallium Nitride (GaN) and Silicon Carbide (SiC) power electronics within a highly collaborative engineering and manufacturing environment.

• Package complex power converters, energy storage systems, and PLC systems using 3D mechanical design tools.
• Build and test complex power converters, energy storage systems, and PLC systems in collaboration with the operations and test teams.
• Design thermal management systems for power electronics, including cold plates, heat exchangers, and overall thermal management systems for large power electronics.
• Perform structural analysis for components, support structures, and ruggedized enclosures subjected to harsh environmental conditions, including shock and vibration.
• Use FEA, CFD, and hand calculations to perform detailed thermal and structural analyses.
• Create, review, and release prototype and production‑level mechanical drawings in accordance with GD&T standards.
• Source vendors and communicate with suppliers to obtain quotes and support procurement of custom mechanical parts.
• Prepare and deliver technical presentations and design reviews for customers and internal stakeholders.
• Create and maintain process documentation and build documentation in conjunction with the operations team to support manufacturing and assembly.
• Write and review mechanical engineering‑focused patents, white papers, and technical conference or journal articles.
• Mentor junior engineers by providing technical guidance, design review feedback, and support in analysis and testing activities.
• Lead cross‑functional teams to develop solid‑state power conversion systems from concept through production.
• Provide technical input into business development activities, including proposal support and technical content for new opportunities.
• Contribute to MW‑scale power converter projects for naval ship applications, including preparation of technical data packages and related documentation.
• Perform structural, thermal, and shock and vibration analyses using tools such as Sim Lab, Creo Simulate, and Creo Flow.
• Support the design of naval shipboard and undersea submersible components, ensuring robust performance in demanding environments.

• Bachelor’s degree in mechanical engineering.
• Experience in mechanical design and 3D modeling for complex electromechanical systems.
• Proficiency with CAD tools for 3D mechanical design, such as Solid Works, Creo, Pro/ENGINEER (Pro‑E), or similar.
• Hands‑on experience with mechanical engineering design for power systems, power electronics, or machine design applications.
• Ability to design thermal management systems for power electronics, including cold plates, heat exchangers, and high‑performance thermal solutions.
• Experience performing structural analysis for components, support structures, and ruggedized enclosures under harsh environmental conditions, including shock and vibration.
• Proficiency in using FEA and CFD tools for thermal and structural analysis, as well as performing supporting hand calculations.
• Ability to create, review, and release production‑quality mechanical drawings in accordance with GD&T standards.
• Experience with manufacturing‑oriented mechanical design and working with on‑site manufacturing in a rapid prototyping environment.
• Strong analytical skills in thermal analysis and mechanical analysis, including use of tools such as ANSYS and Altair.
• Ability to obtain a U.S. Department of Defense security clearance.
• United States citizenship, as required by applicable ITAR program restrictions.

• Graduate‑le…