Senior Mechanical Engineer, Design and Thermal Analyses

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RDE Burnsville, MN, US

17 days ago Requisition

Salary Range: $ To $ Annually

Job Description:

Trystar develops power equipment through cross-functional engineering and manufacturing collaboration. You will connect practical mechanical design with test-grounded thermal analysis to help teams deliver reliable products.

This hands‑on role combines mechanical requirements, design, packaging, CAD, and drawings with independent thermal and fluid modelling, prototype validation, test correlation, and manufacturing handoff. Your assignments support platform development, including power converters, switchboards, and load banks. The opportunity is to develop manufacturable equipment and apply rigorous thermal evaluations to higher power density within limited footprints, not to work exclusively on one product.

You report to a Senior Engineering Manager for RDE Power Distribution, who prioritizes assignments and resolves conflicting project demands. You work as a senior individual contributor, contribute technical mentoring, and support established release decisions; the role does not carry independent product release authority or automatic leadership of all products across sites.

In this role you will:

• Own the mechanical design of assigned products from requirements through preparation of finished-product release packages. Translate requirements into product packaging, part and assembly models, CAD layouts, production drawings, and other controlled mechanical artifacts, with clear ownership of mechanical decisions under established release authority.
• Develop enclosures and assemblies using appropriate materials and processes, including sheet metal, plastics, and extrusions. Design for safety, reliability, manufacturability, serviceability, and reuse across product platforms.
• Coordinate PCB mounting, structural interfaces, access, serviceability, and electrical packaging with electrical and power conversion engineers while maintaining distinct mechanical and electrical design ownership.
• Independently develop and interpret thermal and fluid models, including computational fluid dynamics where appropriate. Define assumptions, boundary conditions, operating cases, acceptance limits, uncertainty before drawing conclusions, and explain the limitations of each result.
• Evaluate air, liquid, immersive, and thermosiphon cooling concepts as applicable. Analyze component temperatures, heat dissipation, flow, and power density within constrained footprints, and convert the results into explicit design decisions.
• Design and integrate thermal‑management components, including cold plates, heat exchangers, busbars, pumps, fans, and thermal control loops. Work with electrical and compliance teams to define an effective power path and manage high‑power heat loads.
• Lead cross‑functional mechanical design reviews for assigned work. Assess DFM, assembly, maintenance access, design robustness, FMEA, AFMEA, IP ratings, seismic requirements, harsh‑environment requirements, and other applicable equipment, product, and safety standards.
• Support NRTL construction reviews and the established design and release process by preparing design packages and objective evidence that the design meets applicable requirements.
• Plan and support prototype builds and validation with the testing team. Design test fixtures; perform required thermal, flow, HALT, vibration, and shock testing; and correlate measured temperatures, flow, and other responses with analytical…