Project Lead Engineer - High Voltage Industrial and Data Centers

About Methode Electronics We are a leading global provider of innovative automotive and industrial electronic products, including center stacks, switch banks, sensors, high-voltage busbars, Battery Disconnect Units (BDU), Integrated Circuit Boards (ICB), park brake actuators, ambient lights, and Center High-Mount Stop Lights (CHMSL). Our commitment to quality, innovation, and sustainability positions us at the forefront of the industry, delivering high-performance power distribution solutions to customers worldwide.

We are seeking a highly qualified Mechanical Engineer to play a crucial role in the Product Development lifecycle of innovative high-voltage power distribution components. This role owns the design, analysis, and validation of critical systems, with a core focus on data center busbars, industrial power pathways, and wire harnesses. Leading projects from concept to production launch, you will collaborate with cross-functional teams and industry experts to ensure designs meet rigorous electrical, thermal, structural, and manufacturing specifications.

• Design & New Product Development (NPD):
  Specify, design, and develop high-voltage components, focusing on data center busbars and high-power wire harnesses. Utilize advanced 3D CAD software to generate detailed models, architectural layouts, and production-ready manufacturing drawings.
• Vertical Busbar Engineering & Attributes:
  Optimize vertical busbar architectures for critical data center infrastructure, ensuring precise execution of core attributes:
  Electrical & Thermal:
  Manage high current density, skin effect, voltage drop constraints and short-circuit current ratings. Mechanical & Structural:
  Design for seismic bracing requirements, structural loading, expansion joints (to handle thermal expansion/contraction across multi-story risers), and joint integrity. Ingress & Insulation:
  Incorporate proper phase isolation, epoxy coating, heat-shrink insulation, and appropriate Ingress Protection (IP) ratings.
• Analysis & Simulation:
  Collaborate with FEA analysts to define model setups, boundary conditions, and assumptions. Interpret and act upon results from thermal (CFD), fluid flow (Moldflow for over moulding), and structural mechanical (stress/strain/vibration) simulations to validate busbar integrity under maximum electrical load and fault conditions.
• Technical Documentation & Standards:
  Apply a comprehensive understanding of Geometric Dimensioning & Tolerancing (GD&T) to detailed component designs. Ensure all technical documentation, tolerance stacks, and engineering drawings strictly comply with industry standards (e.g., ASME Y14.5, ANSI, UL 857 / IEC 61439-6 for busbar trunking systems).
• Materials Expertise:
  Apply functional knowledge of material properties—including copper/aluminum conductivity, plating (tin, silver, nickel), insulation chemistry, and polymer selection—to component design, environmental testing, and qualification processes.
• Project Leadership:
  Lead cross-functional product development gates from concept through production release. Act as the primary technical point of contact, ensuring alignment between cost, timeline, tooling feasibility, and customer specifications.

• Education:
  
  Bachelor’s degree in Mechanical Engineering, Electromechanical Engineering, or a related technical discipline.
• Experience:
  
  5+ years of mechanical design experience in New Product Development, specifically focusing on high-voltage power distribution, industrial busbars, or data center infrastructure.
• CAD/Tools:
  Proficiency in advanced 3D CAD platforms (e.g., Creo, Solid Works, or CATIA) and PLM software.
• Industry Knowledge:
  Strong familiarity with copper fabrication, extrusion, over moulding, and…