Mechanical Engineer

Location: Halethorpe

Job Title:

SR Mechanical Engineer - Power Systems & 3D Electronics Packaging

Job Description

This role focuses on the mechanical design, packaging, and validation of advanced power electronics and energy storage systems used in demanding environments such as land-based, shipboard, airborne, and subsea applications. The Senior Mechanical Engineer will lead the design of 3D electronics packaging, thermal management systems, and ruggedized structures, while also supporting hardware build and test activities. This position offers the opportunity to contribute to cutting-edge wide band gap power electronics, collaborate with cross-functional teams, and mentor junior engineers in a rapidly growing power systems organization.

Responsibilities

* Package complex power converters, energy storage systems, and PLC systems, ensuring robust mechanical integration and serviceability.

* Build and test complex power converters, energy storage systems, and PLC systems in collaboration with electrical and manufacturing teams.

* Design thermal management systems for power electronics, including cold plates, heat exchangers, and overall thermal management systems for large power electronics platforms.

* Perform structural analysis for components, support structures, and ruggedized enclosures operating in harsh environmental conditions, including shock and vibration.

* Use FEA, CFD, and hand calculations to perform detailed thermal and structural analyses that guide design decisions.

* Create, review, and issue prototype and production-level 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 and build documentation in conjunction with the operations team to support repeatable manufacturing and assembly.

* Write and review mechanical engineering-focused patents, whitepapers, and technical conference or journal articles to capture and share technical innovations.

* Mentor junior engineers by providing technical guidance, design reviews, and support in day-to-day engineering 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 strategy.

* Support immediate projects such as megawatt-scale power converters 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.

* Contribute to naval shipboard and undersea submersible component design, ensuring compliance with performance and environmental requirements.

* Work closely with on-site manufacturing in a rapid prototyping environment to validate designs and support continuous improvement.

Essential Skills

* Bachelor's degree in mechanical engineering (graduate work is acceptable in lieu of some work experience).

* Experience in mechanical design and mechanical engineering for complex power systems or related equipment.

* Proficiency in 3D CAD modeling for mechanical design, using tools such as Solid Works, Creo, Pro/Engineer (Pro-E), or equivalent.

* Hands-on experience with packaging of power electronics, energy storage systems, and PLC systems.

* Demonstrated ability to design thermal management systems for power electronics, including cold plates and high-performance heat exchangers.

* Experience performing structural analysis for components, support structures, and ruggedized enclosures subjected to harsh environmental conditions and shock and vibration.

* Proficiency with FEA and CFD modeling software packages for thermal and structural analysis.

* Ability to perform hand calculations to validate and supplement simulation results.

* Experience creating, reviewing, and releasing mechanical drawings in accordance with GD&T standards.

* Familiarity with manufacturing processes and machine design within a power or…