Technical Lead- Mechanical Design

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
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• Drive platform reuse, modularization, and standardization
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• Align with global product roadmaps and customer-specific adaptations
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2. Thermal & Cooling Engineering (Critical for Tier-1)

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• Design high-efficiency cooling systems: Forced air cooling (ducted, sealed systems) Liquid cooling (cold plates, manifolds, CDU integration)
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• Perform Multiphysics simulations using: ANSYS Icepack FloTHERM
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• Optimize junction temperatures for IGBT / SiC devices , magnetics, and capacitors
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• Ensure derating strategy and thermal robustness under worst-case conditions
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3. Mechanical Design & CAD Ownership

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• Lead detailed design using: Creo Siemens NX SolidWorks
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• Develop: 3D CAD models, assemblies, and 2D drawings GD&T, tolerance stack-ups, and design release packages
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• Manage BOM and interface with PLM systems
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4. Design for Excellence (DFX) – Tier-1 Focus

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• Drive: DFM (Manufacturability) DFA (Assembly) DFC (Cost optimization) DFS (Serviceability)
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• Collaborate with global suppliers and contract manufacturers
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• Support sourcing strategy and vendor development
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5. Reliability, Durability & Validation

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• Design for automotive/industrial reliability targets (10–15+ years life)
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• Conduct and support: HALT / HASS Thermal cycling Vibration & mechanical shock tests IP ingress protection validation
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• Perform FEA (structural, vibration, fatigue)
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6. Compliance & Safety (Mandatory Tier-1 Exposure)

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• Ensure compliance with: IEC / UL / ISO standards Environmental & enclosure standards (IP54–IP66)
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• Work with safety teams on: Functional safety (alignment with ISO 26262 principles where applicable) Creepage & clearance coordination with electrical design
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• Support certification and regulatory audits
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7. Cross-Functional Leadership

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• Lead collaboration with: Power electronics and electrical teams Controls & firmware teams Manufacturing, quality, and sourcing teams
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• Interface directly with customers (OEMs, utilities, EPCs)
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• Drive design reviews, DFMEA, and risk mitigation
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8. Program Execution & Ownership

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• Own product lifecycle from: Concept → Prototype → Validation → SOP → Mass production
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• Support APQP processes: DFMEA / PFMEA PPAP documentation
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• Ensure on-time delivery aligned with program milestones
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Required Qualifications

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• Bachelor’s / Master’s in Mechanical Engineering
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• 10–15 years of experience in: Tier-1 automotive / industrial / energy systems companies
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• Proven experience in: High-voltage, high-power systems (800 V to 1500 V DC) Converter systems (inverters, rectifiers, DC-DC)
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Core Competencies

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Technical Depth

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• Advanced thermal management (air & liquid cooling)
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• Structural and vibration design
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• EMI/EMC-aware mechanical design
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• Material science (Al alloys, Cu, thermal interface materials, coatings)
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Process Excellence

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• APQP, DFMEA, PPAP
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• Change management (ECR/ECO)
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• Root cause analysis (8D, Fishbone)
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Domain Knowledge

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• EV fast chargers (DCFC systems)
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• BESS PCS (Power Conversion Systems)
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• Solar central inverters
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• Industrial power supplies
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Preferred Experience

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• Exposure to global Tier-1 environments such as: Bosch Valeo Magna International Delta Electronics ABB
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• Experience with global OEM customers and international project execution
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Leadership Expectations

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• Lead and mentor a team of 5–10 engineers
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• Drive innovation in cooling, packaging, and modular design
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• Influence product cost, reliability, and scalability decisions
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• Act as a technical authority within the organization
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KPIs / Success Metrics

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• First-pass design success (minimal redesign loops)
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• Thermal and reliability performance
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• Cost targets (BOM and manufacturing)
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On-time SOP delivery