Lead Mechanical Design Engineer – Power Converters
Role Summary
As a Lead Mechanical Design Engineer, you will own the end-to-end mechanical design and industrialization of high-power converter products (40 kW rectifier modules to MW-scale central inverters). The role requires deep expertise in automotive-grade design processes, reliability engineering, and global compliance standards, ensuring scalable, cost-optimized, and production-ready solutions.
Key Responsibilities
1. Product Architecture & Platform Strategy
- Define scalable mechanical platforms for:
- Rectifier modules (30–60 kW class)
- Power stacks and converter cabinets
- MW-scale central inverter systems
- Drive platform reuse, modularization, and standardization
- Align with global product roadmaps and customer-specific adaptations
2. Thermal & Cooling Engineering (Critical for Tier-1)
- Design high-efficiency cooling systems:
- Forced air cooling (ducted, sealed systems)
- Liquid cooling (cold plates, manifolds, CDU integration)
- Perform Multiphysics simulations using:
- Optimize junction temperatures for IGBT / SiC devices, magnetics, and capacitors
- Ensure derating strategy and thermal robustness under worst-case conditions
3. Mechanical Design & CAD Ownership
- Lead detailed design using:
- Creo
- Siemens NX
- SolidWorks
- Develop:
- 3D CAD models, assemblies, and 2D drawings
- GD&T, tolerance stack-ups, and design release packages
- Manage BOM and interface with PLM systems
4. Design for Excellence (DFX) – Tier-1 Focus
- Drive:
- DFM (Manufacturability)
- DFA (Assembly)
- DFC (Cost optimization)
- DFS (Serviceability)
- Collaborate with global suppliers and contract manufacturers
- Support sourcing strategy and vendor development
5. Reliability, Durability & Validation
- Design for automotive/industrial reliability targets (10–15+ years life)
- Conduct and support:
- HALT / HASS
- Thermal cycling
- Vibration & mechanical shock tests
- IP ingress protection validation
- Perform FEA (structural, vibration, fatigue)
6. Compliance & Safety (Mandatory Tier-1 Exposure)
- Ensure compliance with:
- IEC / UL / ISO standards
- Environmental & enclosure standards (IP54–IP66)
- Work with safety teams on:
- Functional safety (alignment with ISO 26262 principles where applicable)
- Creepage & clearance coordination with electrical design
- Support certification and regulatory audits
7. Cross-Functional Leadership
- Lead collaboration with:
- Power electronics and electrical teams
- Controls & firmware teams
- Manufacturing, quality, and sourcing teams
- Interface directly with customers (OEMs, utilities, EPCs)
- Drive design reviews, DFMEA, and risk mitigation
8. Program Execution & Ownership
Own product lifecycle from:
Concept Prototype Validation SOP
- Support APQP processes:
- DFMEA / PFMEA
- PPAP documentation
- Ensure on-time delivery aligned with program milestones
Required Qualifications
- Bachelor’s / Master’s in Mechanical Engineering
- 10–15 years of experience in:
- Tier-1 automotive / industrial / energy systems companies
- Proven experience in:
- High-voltage, high-power systems (800 V to 1500 V DC)
- Converter systems (inverters, rectifiers, DC-DC)
Core Competencies
Technical Depth
- Advanced thermal management (air & liquid cooling)
- Structural and vibration design
- EMI/EMC-aware mechanical design
- Material science (Al alloys, Cu, thermal interface materials, coatings)
Process Excellence
- APQP, DFMEA, PPAP
- Change management (ECR/ECO)
- Root cause analysis (8D, Fishbone)
Domain Knowledge
- EV fast chargers (DCFC systems)
- BESS PCS (Power Conversion Systems)
- Solar central inverters
- Industrial power supplies
Preferred Experience
- Exposure to global Tier-1 environments such as:
- Bosch
- Valeo
- Magna International
- Delta Electronics
- ABB
- Experience with global OEM customers and international project execution
Leadership Expectations
- Lead and mentor a team of 5–10 engineers
- Drive innovation in cooling, packaging, and modular design
- Influence product cost, reliability, and scalability decisions
- Act as a technical authority within the organization
KPIs / Success Metrics
- First-pass design success (minimal redesign loops)
- Thermal and reliability performance
- Cost targets (BOM and manufacturing)
On-time SOP delivery
