Senior Staff Mechanical Design Engineer

Senior Staff Mechanical Design Engineer

We are seeking a skilled Senior Staff Mechanical Design Engineer to join our team and contribute to the development of power electronics products.

The primary function of this position is to own mechanical architecture and design strategy across multiple power converter platforms and voltage classes, including designing custom mechanical parts across our power converter modules and our system design. You will serve as the technical authority and escalation point for Staff and Senior mechanical engineers on the organization's toughest design problems, and will work closely with cross-functional teams, including manufacturing, test engineers, quality, and new product introduction (NPI) as the primary design point of contact to support and guide these teams as they work with our designs.

Strong ability to understand problems, synthesize inputs from cross-functional stakeholders, and cut through the noise and connect the dots to develop a clear plan of action is key in this role.

• Own the multi-generation mechanical technology roadmap across product platforms.
• Mentor Staff and Senior mechanical engineers and lead design-review governance.
• Represent mechanical engineering in executive and leadership technical reviews.
• Drive build-vs-buy and make-vs-buy strategy at the program level.
• Model and design complex electro-mechanical parts, including plastics, sheet metal, insulators, magnetic components, and high-voltage connectors, creating detailed 3D and 2D designs using CAD software.
• Serve as the primary design point of contact for cross-functional teams, guiding their work and connecting the dots between many inputs to develop a clear plan of attack on problems.
• Collaborate cross-functionally with electrical, thermal, firmware and controls, manufacturing, test, quality, reliability, and industrial design teams.
• Lead prototype development, fabrication, assembly, and mechanical testing of new designs.
• Drive trade studies to inform system-level decisions on design architecture, materials, and manufacturing processes.
• Guide selection for structural, thermal, and electrical compatibility in high-voltage environments.
• Define and execute validation test plans including structural, thermal, and environmental testing.
• Support root-cause analysis of design issues in pilot or production builds and lead iterative improvements.
• Perform mechanical design analysis, including structural FEA, thermal CFD, vibration, and fatigue assessments.
• Solve packaging challenges involving electrical isolation, sealing, thermal dissipation, EMI/EMC shielding, and mechanical shock/vibration.
• Create engineering documentation, tolerance stacks, BOMs, and release packages through PLM systems.
• Work closely with suppliers to optimize DFM, DFA, and tooling strategies for high-volume production.
• Contribute to the layout and design of integrated cooling systems including cold plates, thermal interfaces, and airflow paths.
• Develop assembly procedures and manufacturing instructions to support scalable production.
• Participate in mechanical FMEA and DVP&R activities across product lifecycle stages.
• Work with quality and reliability teams to meet performance, lifecycle, and safety targets.
• Set mechanical design standards and DFM/DFA guidelines used across the engineering organization.

• Bachelor's or Master's degree in Mechanical Engineering or a related field.
• 10+ years of experience in mechanical design for power electronics, automotive, industrial, or energy products.
• Expertise in CAD modeling using 3D EXPERIENCE (CATIA V6/V5), Solid Works, NX, or Creo.
• Deep understanding of mechanical fundamentals—statics, dynamics, heat transfer, and materials.
• Ability to understand the root of a problem based on first-principles understanding – not just what people are telling you their opinion of the problem is.
• Proficiency in GD&T, tolerance analysis, and DFM/DFA principles.
• Experience designing enclosures for IP-rated or outdoor-rated power equipment.
• Experience with high-volume manufacturing processes such as injection molding, die casting, extrusion, and sheet metal forming.
• Working knowledge of materials: metals (aluminum, steel), plastics, ceramics, gaskets, potting compounds.
• Hands-on experience taking designs from prototype through production deployment.
• Familiarity with PLM systems (3D EXPERIENCE, Windchill, etc.) and engineering change workflows.
• Comfortable with root-cause analysis, failure mode resolution, and mechanical reliability testing.
• Strong communication skills and ability to lead cross-functional design reviews and technical deep-dives.
• Demonstrated technical leadership without direct reports (e.g., technical lead, design authority, or equivalent role).
• Experience directing the work of junior engineers on large efforts.
• Prior experience collaborating with suppliers on tooling development, DFM feedback, and tolerance negotiations.
• Familiarity with PCBAs, connectors, and mechanical integration of high-density…