Senior Mechanical Engineer

Job Description Summary

We are seeking a Senior Mechanical Engineer to lead the packaging, structural, and thermal design of next-generation high-power electrical systems, including inverters, converters, variable frequency drives, and energy storage solutions. This role sits at the intersection of electrical performance and physical implementation, with responsibility for developing cooling systems, enclosures, and packaging architectures for high-density power electronics operating in demanding environments.

As part of the Advanced Concepts and Technology team, you will apply first-principles engineering, FEA/CFD modeling, rapid prototyping, and hands‑on testing to solve complex challenges in heat transfer, structural integrity, electronics packaging, and manufacturability. The role supports advanced applications such as energy storage, propulsion systems, naval/marine power systems, and building block converters, including designs using SiC and GaN devices.

This position requires deep expertise in mechanical integration, and product development, with a strong focus on practical, scalable, design-for-manufacturing solutions. You will also help strengthen the team through mentoring and training junior engineers.

• Review customer requirements and developmechanical/thermal specifications for high-power converter systems acrossindustrial, marine, renewable, and navalapplications.
• Lead system architecture and trade studiesthat influence component selection, materials, board layout, and packaging design.
• Own the thermal management strategy for power converters, including heat sinks, cold plates, heat exchangers, and thermal interface materials.
• Perform and guideFEA/CFD modeling to evaluate cooling performance, fluid flow, thermal balance, structural integrity, shock, vibration, and thermal stress.
• Develop and validatecooling loop hardware and thermal solutions formagnetics, power devices, and PCBsthrough testing, instrumentation, and simulation correlation.
• Designelectromechanical assembliessuch as ruggedized enclosures, busbars, connectors, insulation systems, structural supports, and PCB mounting solutions for harsh environments.
• Ensure designs meethigh-voltage safety, creepage/clearance, EMI, shock/vibration, and environmental requirements while balancing performance, cost, and manufacturability.
• Create and execute test plans, oversee prototype builds, perform lab-based validation, and correlate physical test data with simulation results.
• Drive Design for Manufacturability / Assembly (DFM/DFA), manage BOMs and technical documentation, and support manufacturing, sourcing, supplier quality, and final acceptance testing.
• Collaborate across electrical, systems, controls, manufacturing, and test teams, lead design reviews, and mentor junior engineers in mechanical and thermal design best practices.

Minimum Qualifications

• Engineering degree in Mechanical Engineering from an accredited university with an emphasis in mechanical design of electrical systems with at least 6+ years’ experience in electrical engineering and/or power electronics packaging.
• 10+ years (total experience) of experience in mechanical design for electrical equipment, conversion systems, and high-power applications.
• 3+ years of experience with 3D mechanical design tools, including Windchill/Creo, ANSYS Workbench, ANSYS Electronics Desktop, COMSOL, ANSYS Mechanical, and Fluent, with the ability to apply these tools to complex converter systems.
• 2+ years of experience with insulation standards, creepage and clearance requirements, and core principles of electronics packaging as it pertains to the mechanical design of Variable Frequency Drives (VFDs) and Power Electronic components such as PCBs.
• 2+ years of designing enclosures for…