Senior Mechanical Design Engineer

About the role

Sr. Mechanical Design Engineer | Power Electronics Products & Systems Role Purpose Design and deliver robust, thermally efficient, and manufacturable mechanical solutions for power electronics products and systems, ensuring reliability, safety, serviceability, and compliance across indoor and outdoor deployments. Key Responsibilities 1. Mechanical Architecture & Enclosure Design Design product and system-level mechanical architecture for: Solar inverters (string & central) PCS & BESS containers EV chargers (AC/DC) Electrolysers & power supply cabinets Develop enclosures, cabinets, skids, and container layouts. Ensure IP protection, corrosion resistance, and environmental robustness. 2. Thermal & Cooling Design Design thermal management solutions: Forced air cooling Liquid cooling (cold plates, heat exchangers) Perform thermal simulations (CFD) and support validation. Optimize airflow paths, heat sink design, and component placement. 3. Structural & Mechanical Analysis Perform structural analysis for: Static & dynamic loads Transportation & seismic conditions Ensure compliance with wind, seismic, and shock/vibration requirements. Design for safe lifting, handling, and installation. 4. Integration with Electrical & Control Systems Coordinate with electrical and control teams on: Component placement & clearances Cable routing and bending radius EMI shielding & segregation Ensure creepage, clearance, and safety requirements are mechanically supported. 5. DFM, DFA & Industrialization Design for manufacturability, assembly, and serviceability. Select materials and finishes considering cost, durability, and environment. Support prototype builds, NPI, and production ramp-up. Drive cost reduction and weight optimization initiatives. 6. Testing, Validation & Compliance Support mechanical and environmental testing: Thermal cycling IP / ingress tests Vibration & shock tests Support certification to IEC, UL, and ISO standards. Resolve mechanical field issues and drive corrective actions. 7. Documentation & Configuration Control Prepare and maintain: 3D models & 2D drawings BOMs & assembly instructions Installation and service manuals Ensure proper revision and change management. Key KPIs Thermal performance & reliability First-pass build success Cost & weight targets Field failure rate Education & Experience BE / BTech in Mechanical Engineering 5–12+ years in mechanical design for power electronics or industrial equipment Experience in Enclosure & cabinet design, Strong understanding in Thermal management & CFD, Structural analysis CAD tools (Creo, SolidWorks, NX) DFM/DFA principles Preferred Industry Background Solar inverter OEMs PCS / BESS system manufacturers EV charging infrastructure Industrial power electronics Preferred Experience Worked on 30+ kW-level converters for EV chargers, ESS, solar inverters, onboard chargers. Knowledge of automotive ISO 26262, IEC 61800, IEC 61000 standards (preferred). Exposure to SiC/GaN based systems. Experience with FPGA or RTOS is a plus. ----------------------------------------End of Document------------------------------------

What you’ll do

• Design mechanical architecture and enclosures for power electronics products
• Develop thermal management solutions including forced air and liquid cooling
• Perform structural analysis ensuring compliance with wind, seismic, and vibration standards
• Coordinate mechanical integration with electrical and control systems
• Drive DFM/DFA for manufacturability, cost reduction, and weight optimization
• Support testing, validation, and certification to IEC, UL, ISO standards
• Maintain 3D models, drawings, BOMs, and documentation

What you’ll bring

• 7-11 years mechanical design for power electronics
• Enclosure and cabinet design experience
• Thermal management and CFD simulation expertise
• Structural analysis for static, dynamic, seismic loads
• Proficiency with CAD tools (Creo, SolidWorks, NX)
• DFM/DFA principles application
• Experience with solar inverters, PCS/BESS, EV chargers

Skills

Education

BE / BTech in Mechanical Engineering