Mechanical Design Engineer

Tech Lead -Mechanical Design | Power Electronics Product & Systems (P11b)

Role

Provide end-to-end leadership for mechanical engineering of power electronics products and integrated systems, ensuring robust mechanical architecture, effective thermal management, environmental protection, manufacturability, and lifecycle reliability across high-power, high-density electrical platforms (AC-DC/DC-DC Converters, EV Chargers and Industrial Power Electronics products.)

Key Responsibilities

1. Mechanical & Thermal Architecture Leadership

• Define mechanical system architecture for:High Voltage EV Chargers (AC, DC Fast, Ultra-Fast)Solar Inverters (String & Central)Automotive On-board Chargers/ Drivetrain inverter /MCU enclosure designindustrial PE products
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• Own thermal management strategy:Natural & forced air coolingLiquid cooling (cold plate, immersion where applicable)Heat exchanger and airflow optimization
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• Define enclosure concepts, IP ratings, corrosion protection, and seismic/wind load compliance.
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2. Product Engineering & Execution

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• Lead teams covering:Mechanical Design & CADPackaging & Industrial Design Thermal & CFD EngineeringStructural & Sheet-Metal Design
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• Understand and implement mechanical design standards, guidelines, and review processes.
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• Drive power density improvements through optimized packaging.
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• Ensure design trade-offs between cost, thermal performance, reliability, acoustics, and serviceability.
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3. Product Development Lifecycle Ownership

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• Own mechanical development across:Requirements → Concept → Detailed Design → Prototype → Validation → Production
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• Implement V-Model / Stage-Gate / APQP processes.
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• Drive Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Serviceability (DFS).
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• Lead value engineering and cost-reduction initiatives.
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• Prepare and maintain:3D models & 2D drawingsBOMs & assembly instructionsInstallation and service manuals
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• Ensure proper revision and change management.
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4. Thermal, Reliability & Environmental Validation

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• Own thermal validation plans (steady-state, transient, derating analysis).
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• Coordinate with CFD team - Given input simulations and correlation with physical testing.
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• Select heatsinks, cooling methods that are manufactural
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• Ensure compliance with:Temperature rise limitsNoise & vibration requirementsEnvironmental tests (IP, salt mist, humidity, dust)
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• Perform/Coordinate structural analysis for:Static & dynamic loadsTransportation & seismic conditionsEnsure compliance with wind, seismic, and shock/vibration requirements.Design for safe lifting, handling, and installation.
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5. Integration with Electrical & Control Systems

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• Coordinate with electrical and control teams on:Component placement & clearancesCable routing and bending radiusEMI shielding & segregation
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• Ensure creepage, clearance, and safety requirements are mechanically supported.
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6. Manufacturing, Quality & Field Support

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• Support NPI, pilot builds, and production ramp-up.
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• Drive mechanical failure analysis, field issue RCA, and corrective actions.
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• Work with supply chain on:Vendor qualificationLocalization & alternate sourcingTooling and fixture development
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• Improve yield, assembly time, and cost in production.
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7. Cross-Functional & Business Engagement

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• Work closely with:Electrical & Power Electronics EngineeringCFD/Thermal, Structural Analysis teamsSystems & ControlsManufacturing, Quality, and Supply Chain
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• Act as mechanical authority in customer and certification discussions.
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• Support pre-sales and customization efforts.
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• Build and mentor a high-performance mechanical engineering organization.
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Education

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• BE / BTech in Mechanical Engineering
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• MTech / MS preferred
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Experience

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• 8+ years in mechanical engineering for power electronics or industrial products
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• Proven leadership in high-power, thermally constrained systems
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• Experience from concept to mass production environments
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• Mechanical Design, Thermal Engineering, Packaging & Validation
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• Should have handled team of mechanical design
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• Should have experience in EV Charger OEMs and Industrial Power Electronics Companies.
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Technical Competencies

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• Thermal management of power electronics
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• Solidworks/AutoCAD
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• Understanding CFD tools (ANSYS, Flotherm, Icepak, etc.)
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• Sheet metal, castings, plastics, and structural design
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• Enclosure design (IP65/IP66/IP67)
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• Shock, vibration, seismic & wind load analysis
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• Acoustic noise reduction
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Leadership & Behavioural Skills

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• Strong system-level thinking
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• Decision-making under technical and cost constraints
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• People leadership & mentoring
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• Cross-functional collaboration
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• Continuous improvement mindset