Senior Design Engineer- Mechanical (Power Electronics products)

Role overview

Key Responsibilities:

• Develop detailed mechanical designs for power electronics packaging which includes enclosures, racks, heatsinks, cooling systems, shock mounts and internal component mounts.
• Design for manufacturability (DFM), assembly (DFA), reliability, and thermal fatigue limits; contribute to DFMEA and DFR initiatives and contribute to continuous improvement initiatives
• Perform advanced

  structural analysis

  using FEA tools to ensure mechanical integrity and reliability, including:
• Static (linear and non-linear)
• Dynamic analysis (random vibration, sine sweep, PSD response)

• Shock and impact assessments

  ,
• fatigue analysis for lifecycle prediction

• Structural optimization

  for Mounting and interface design at the system and internal component level
• Develop robust

  thermal management systems

  , including:
• Liquid or air-cooled solutions
• Thermal network modelling
• CFD-based conjugate heat transfer analysis
• Pressure drop and hydraulic resistance calculations
• Experimental validation to ensure system reliability and performance.
• Collaborate with cross functional teams to ensure seamless integration, manufacturability by meeting safety, environmental and EMC/EMI requirements.
• Support DFM/DFT initiatives and work with suppliers to drive cost-effective, manufacturable, and scalable designs.
• Support prototype development, lab testing, and validation related to mechanical/thermal performance
• Select materials and finishes for thermal performance, corrosion resistance, and regulatory compliance.
• Ensure mechanical compliance with relevant standards such as IP/NEMA ratings,

  IK ratings

  IEC/UL safety norms, and thermal/environmental durability tests (IEC 60068 series)
• Integrate mechanical-electrical interfaces, ensuring alignment of creep age/clearance and EMI/EMC constraints.
• Develop and maintain 3D/2D CAD designs, detailed drawings, Bills of Materials (BOM) comprehensive technical documentation throughout the product development lifecycle

Required Qualifications & Experience

• Bachelor’s or Master’s degree in Mechanical Engineering or a related discipline.
• 8+ years of experience in mechanical design with a focus on power electronics packaging and thermal management, preferably in automotive, renewable energy, or industrial sectors.
• Proficiency in CAD software (SolidWorks, Creo, CATIA) and PLM systems
• Strong hands-on skills with FEA (ANSYS, Abaqus) and CFD (Fluent, FloTHERM or equivalent)
• Expertise of thermal management strategies for high-power applications including liquid/air cooling, heat pipes, TIMs, thermal resistance/ network modelling and pressure drop/hydraulic resistance calculations
• Familiarity with electrical isolation and creepage/clearance design constraints in high-voltage enclosures.
• Experience with IP/IK compliance design, mounting interface engineering, and ruggedization practices.
• Experience in supplier coordination, Deep understanding of manufacturability and assembly (DFM/DFMEA) principles, fatigue life design and hands-on experience with GD&T, material selection, and tolerance analysis.
• Excellent problem-solving skills and ability to work collaboratively in cross-functional teams

Preferred Qualifications

• Experience with high-voltage electrical systems packaging, bus bar design, integration of SiC/GaN-based modules and safety considerations.
• Exposure to rapid prototyping including fixture design, and testing methods related to thermal performance.
• Familiarity with pressure drop and flow loop design for liquid cooling systems.
• Experience in designing modular racks, IP-rated enclosures, and cable/harness routing within constrained environments.
• Familiarity with design standards such as UL 508A, IEC 60529 (IP ratings), ISO 16750, and IPC guidelines for mechanical assemblies.
• Strong documentation, communication and collaboration skills across cross-functional teams