Senior Mechanical Engineer

Senior Mechanical Engineer

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 thermal management, 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.

Job Description

Review customer requirements and develop mechanical/thermal specifications for high-power converter systems across industrial, marine, renewable, and naval applications. Lead system architecture and trade studies that 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 guide FEA/CFD modeling to evaluate cooling performance, fluid flow, thermal balance, structural integrity, shock, vibration, and thermal stress. Develop and validate cooling loop hardware and thermal solutions for magnetics, power devices, and PCBs through testing, instrumentation, and simulation correlation. Design electromechanical assemblies such as ruggedized enclosures, busbars, connectors, insulation systems, structural supports, and PCB mounting solutions for harsh environments. Ensure designs meet high-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 and thermal 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 and thermal design for electrical equipment, conversion systems, and high-power applications. 3+ years of experience with 3D mechanical and thermal 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 housing electronic equipment, ranging from individual modules to system level enclosures. Including knowledge of manufacturing and fabrication processes, such as machining, sheet metal fabrication, welded structures, etc. 2+ years of experience performing mechanical and thermal analysis for power converter components, subsystems, and converter systems.

Desired Characteristics

Comprehensive understanding of military standards, such as MIL-DTL-917F, MIL-DTL-2036E, MIL-STD-1472, etc. Must be able to demonstrate clear knowledge of the specifications and know challenges and design features to enable compliance to the specifications. Thorough understanding of DFM methodologies. Proven track record of designing products tailored to meet military standards. Excellent communication skills, articulate in simplifying complex problems Ability to multi-task on a variety of projects to tight schedule. Excellent hands on debug skills, ability to get things to work. Innovative and inventive in developing intellectual properties (IPs). Willingness to learn, embrace, and utilize AI to enhance engineering and increase productivity.