Sr. Mechanical Design Engineer

Sr. Mechanical Design Engineer

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.

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