Mechanical Design Engineer - Power Electronics and EV Chargers

About the Role

We are looking for a seasoned Mechanical Design Engineer to lead the mechanical engineering aspects of power electronics products and integrated systems. This role involves developing robust mechanical architectures, managing thermal performance, ensuring environmental protection, and maintaining manufacturability and reliability throughout the product lifecycle. Key products include high-power, densely packed electrical platforms such as AC-DC/DC-DC converters, EV chargers, and industrial power electronics.

Key Responsibilities

• Lead and define mechanical and thermal system architectures for diverse products including High Voltage EV Chargers (AC, DC Fast, Ultra-Fast), Solar Inverters (String & Central), automotive onboard chargers, drivetrain inverters, MCU enclosures, and industrial power electronics.
• Develop and oversee thermal management strategies employing natural and forced air cooling as well as liquid cooling techniques such as cold plate and immersion cooling where applicable.
• Design enclosure concepts focusing on IP protection ratings, corrosion resistance, and compliance with seismic and wind load standards.
• Manage cross-functional teams covering mechanical design, CAD, packaging and industrial design, thermal and CFD engineering, structural and sheet-metal design.
• Implement mechanical design standards, optimize power density through advanced packaging methods, and balance trade-offs involving cost, thermal performance, reliability, acoustics, and serviceability.
• Supervise the entire mechanical product development lifecycle, from requirements definition to concept development, detailed design, prototyping, validation, and production.
• Adhere to development processes such as V-Model, Stage-Gate, and APQP and drive design for manufacturability, assembly, and serviceability principles.
• Champion value engineering and cost reduction initiatives.
• Prepare and manage 3D models, 2D drawings, BOMs, assembly instructions, and installation/service manuals ensuring thorough revision and change management.
• Lead thermal validation including steady-state, transient, and derating analyses coordinating with CFD teams for simulation correlation.
• Select manufacturable cooling components such as heatsinks and manage compliance with temperature, noise, vibration, and environmental test requirements including IP ratings and exposure to salt mist, humidity, and dust.
• Conduct or coordinate structural analyses to address static, dynamic, transportation, seismic, wind, shock, and vibration load considerations.
• Design for safe handling, lifting, and installation procedures.
• Collaborate closely with electrical and control system teams to ensure component placement, cable routing, EMI shielding, clearance, creepage, and safety standards are fully supported mechanically.
• Support new product introduction, pilot builds, and production ramp-up phases.
• Drive root cause analysis for mechanical failures, field issue resolution, and corrective actions.
• Partner with supply chain to qualify vendors, localize and identify alternative suppliers, and develop tooling and fixtures.
• Lead efforts to improve yield, reduce assembly times, and lower production costs.
• Engage cross-functionally with electrical, thermal, structural, systems, manufacturing, quality, supply chain teams, and serve as the mechanical authority in customer and certification discussions.
• Provide support for pre-sales and customized product configurations.
• Build and mentor a capable and high-performing mechanical engineering team.

Educational and Professional Qualifications

• Bachelor's degree in Mechanical Engineering is required; Master's degree (MTech/MS) preferred.
• A minimum of eight years' experience in mechanical engineering, specifically within power electronics or industrial product domains.
• Demonstrated leadership experience managing mechanical design teams and working across the entire product lifecycle from concept through mass production.
• Previous experience with EV charger OEMs and industrial power electronics companies is essential.

Technical Expertise

• Expertise in thermal management for power electronics applications.
• Proficient in CAD software such as SolidWorks and AutoCAD.
• Working knowledge of CFD simulation tools like ANSYS, Flotherm, Icepak.
• Design experience with sheet metal, castings, plastics, and structural components.
• Enclosure design capabilities for IP ratings IP65 through IP67.
• Competence in shock, vibration, seismic, and wind load analyses.
• Knowledge of acoustic noise reduction techniques.

Leadership and Behavioral Attributes

• Strong system-level thinking and holistic problem-solving approach.
• Ability to make balanced decisions considering technical specifications and cost constraints.
• Proven people leadership and mentoring skills.
• Excellent collaborative skills across multidisciplinary teams.
• Commitment to continuous improvement and innovation.