Lead Mechanical Engineer

Lead Mechanical Engineer

Eaton's ES AMER Sector Integration division is currently seeking a hands-on Lead Mechanical Engineer to support the development of advanced EDLC supercapacitor products, with the primary focus on EDLC modules and their internal mechanical components. The product line also includes cylindrical EDLC cells, module packs, and module rack systems operating up to 1500 VDC, which may be series-combined into medium-voltage energy storage systems. This role will take place out of our office in Pleasanton, CA. We are able to offer relocation assistance for qualified candidates within the United States.

This role requires an experienced mechanical engineer who can own and execute the full mechanical product design cycle, from customer requirements and concept development through detailed design analysis, material selection, DFx implementation, prototype builds, product release, manufacturing development, and transfer to mass production. The candidate will work globally with internal engineering teams, suppliers, manufacturing partners, and customers, with travel up to 15%.

The ideal candidate will have strong mechanical design fundamentals, practical hands-on product development experience, and knowledge of medium- and high-volume manufacturing processes for semi-finished goods and components used in EDLC cell, module, pack, and rack assemblies. Experience selecting materials and manufacturing processes during the design phase is a strong plus. Knowledge of wiring, connectors, wire harnesses, manufacturing equipment, and basic control systems such as PLCs is preferred.

The expected annual salary range for this role is $117000 - $172000 a year. Please note the salary information shown above is a general guideline only. Salaries are based upon candidate skills, experience, and qualifications, as well as market and business considerations.

Key Responsibilities:

• Lead hands-on mechanical design and development of EDLC modules and internal components, packs, and high-voltage module rack systems operating up to 1500 VDC.
• Own the full mechanical product development cycle, including customer requirements, concept development, mechanical architecture, detailed design analysis, material selection, DFx, prototype builds, validation support, engineering release, manufacturing development, and transfer to mass production.
• Develop 3D CAD models, 2D drawings, assembly drawings, BOMs, specifications, and release documentation using SolidWorks and ENOVIA or similar PLM systems.
• Design module-level mechanical components such as cell holders, retention systems, compression features, module frames, housings, covers, brackets, busbar supports, insulation barriers, thermal features, and service-access features.
• Design and specify wiring, connectors and wire harnesses.
• Collaborate with cross functional teams to integrate sensors, monitoring electronics, manufacturing equipment interfaces, automation equipment, and PLC-controlled equipment as needed.
• Support high-voltage and medium-voltage system integration, including mechanical packaging for creepage, clearance, insulation, grounding, bonding, touch-safe design, serviceability, thermal management, and structural integrity.
• Apply DFx principles to create robust, cost-effective, manufacturable, and serviceable designs suitable for medium- and high-volume production.
• Select materials and manufacturing processes during the design phase, considering performance, reliability, manufacturability, cost, tooling, process capability, yield, and long-term product quality.
• Work with suppliers and manufacturing teams to develop fabricated semi-finished goods and components used in EDLC cell, module, pack, and rack assemblies.
• Lead prototype builds and engineering builds. Support pilot builds, production launch, manufacturing process development, tooling, fixtures, work instructions, inspection requirements, and production transfer.
• Interface globally with internal engineering teams, suppliers, manufacturing partners, and customers; support technical reviews, design reviews, issue resolution, supplier qualification, and production readiness activities.
• Participate in design reviews, manufacturability reviews, tolerance reviews, technical risk assessments, DFMEA/PFMEA activities, root-cause analysis, corrective actions, and continuous improvement efforts.
• Travel domestically and internationally up to 15% as required.

Qualifications:

Required (Basic) Qualifications:

• Bachelor's degree in Mechanical Engineering or related engineering discipline from an accredited institution.
• Minimum 5 years of mechanical engineering experience in product development, manufacturing engineering, systems integration, industrial equipment, energy storage, electromechanical products, or related engineering fields.
• Eaton will not consider applicants for employment immigration sponsorship or support for this position. This means that Eaton will not support any CPT, OPT, or STEM OPT plans, F-1 to H-1B, H-1B cap registration, O-1, E-3, TN status, I-485 job portability, etc.

Preferred Qualifications:

• Master's degree in Mechanical Engineering or related discipline from an accredited institution.

Skills:

• Experience with supercapacitor modules or battery modules, battery systems, energy storage systems, or high-voltage electrical equipment.
• Experience designing products operating up to 1500 VDC or used in medium-voltage energy storage systems.
• Knowledge of high-voltage mechanical packaging, insulation, creepage, clearance, grounding, bonding, and touch-safe design.
• Experience with supercapacitors, battery module design, cylindrical cell design, pack design, rack design, or industrial cabinet design.
• Experience designing mechanical assemblies for vibration, shock, transportation loads, or harsh operating conditions.
• Experience with wiring, connectors, cable routing, and wire harness integration.
• Basic familiarity with manufacturing equipment, automation systems, control systems, and PLC-based equipment.
• Experience selecting materials and manufacturing processes during the product design phase.
• Experience with thermal management for energy storage or power electronics systems.
• Experience working with global suppliers, contract manufacturers, and customers.
• Familiarity with applicable UL, IEC, CE, or other safety and compliance standards.

Key Competencies:

• Willingness to travel up to 15%, including domestic and international travel.
• Hands-on mechanical design capability.
• EDLC module and internal component design.
• Full product lifecycle ownership.
• System-level engineering mindset.
• High-voltage packaging awareness.
• Strong DFx and manufacturability mindset.
• Practical materials and process selection experience.
• Medium- and high-volume manufacturing experience.
• Supplier, customer, and global engineering communication.
• Strong CAD and engineering documentation discipline.
• Prototype build and manufacturing transfer experience.
• Cross-functional problem solving.
• Basic understanding of wiring, connectors, harnesses, controls, and manufacturing equipment interfaces.