Principal Mechanical Engineer

Principal Mechanical Engineer

Advanced Energy is a global leader in the design and manufacturing of highly engineered, precision power conversion, measurement and control solutions for mission-critical applications and processes. AE's power solutions enable customer innovation in complex applications for a wide range of industries including semiconductor equipment, industrial, manufacturing, telecommunications, data center computing and healthcare. Advanced Energy has devoted four decades to perfecting power for its global customers and is headquartered in Denver, Colorado.

As a Principal Mechanical Engineer in the Plasma Power Group, you will lead the design, analysis, and validation of mechanical systems for RF generator systems used in plasma processing applications. You will drive innovation in thermal management, materials selection, and mechanical design for high-power electronics in complex environments. This role requires cross-functional collaboration, technical leadership, and mentoring of junior engineers. You will influence product architecture, ensure manufacturability, and contribute to the success of next-generation plasma power solutions.

Responsibilities:

• Lead mechanical engineering efforts across all phases of the product development lifecycle
• Architect and optimize thermal management systems including cold plates, heat exchangers, and active cooling solutions
• Perform advanced simulations (thermal, structural, fluid flow) using tools like Ansys or COMSOL; validate results through empirical testing
• Design mechanical components using Solid Works or equivalent CAD tools, applying GD&T and tolerance stack-up analysis per ANSI Y14.5
• Develop mechanical designs for sheet metal, machined, molded, extruded, stamped, and 3D-printed parts
• Design and route power and communication cables to meet system, regulatory, and EMI requirements
• Create and manage complex Bills of Materials (BOMs) and configuration control across multiple product lines
• Collaborate with suppliers and internal teams to ensure manufacturability, cost-effectiveness, and supply chain resilience
• Specify and execute experiments to validate design concepts and performance
• Apply DFM/DFA principles to improve manufacturability, serviceability, and reliability
• Evaluate and select materials for high RF field environments and harsh operating conditions
• Mentor junior engineers and contribute to technical reviews, design standards, and best practices
• Communicate effectively and work collaboratively with cross-functional teams including electrical engineering, RF engineering, supply chain, compliance, reliability, product management, factory/operations, and leadership
• Interface with customers and OEMs to define and negotiate mechanical design requirements

Work Environment:

Location:

Onsite in Fort Collins, CO. Work is split between a standard office environment, engineering lab, and/or clean room. Occasional domestic and international travel may be required for supplier visits, testing, or customer support.

Qualifications:

Expert proficiency in Solid Works or equivalent 3D CAD software. Advanced knowledge of tolerance analysis and GD&T (ANSI Y14.5). Strong hands-on experience with lab testing, instrumentation, and data analysis. Ability to self-manage projects from concept to release, including schedule and cost control. Proficiency with Ansys, COMSOL, or similar simulation tools preferred. Background in electronics packaging, RF systems, or high-voltage/high-power applications preferred.

Experience:

10+ years of mechanical engineering experience. Proven experience designing and validating thermal management systems. Experience managing BOMs and configuration control in a multi-product environment. Experience with materials selection for high RF field and high-temperature environments preferred. Strong background in DFM/DFA and reliability engineering preferred. Experience working directly with customers to define and validate design requirements preferred.

Education:

Minimum of Bachelor's degree in mechanical engineering. MS or PhD preferred.

Compensation:

As required by multiple state pay transparency laws, Advanced Energy provides a reasonable range of compensation for each job posting. Actual compensation is influenced by an array of factors including, but not limited to, skill set, level of experience, and specific office location. The range of starting pay for this role is $130,000 - $200,000 per year.

Benefits:

In the U.S., we offer a rich benefits package that includes:
Medical - multiple medical plans are available to choose from. Short and long-term disability and life insurance. Health savings and flexible spending accounts. Generous time off policy starting with 3 weeks of paid vacation, 7 days of paid sick time, and 12 paid holidays. 8 hours of paid volunteer time off. 8 weeks of paid parental leave for both Moms and Dads.

Company matched 401(k). Tuition reimbursement. Expanded mental health coverage and employee assistance programs. Other voluntary benefits…