Mechanical Design Engineer

Job description

Tech Lead -Mechanical Design | Power Electronics Product & Systems (P11b)RoleProvide 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 Responsibilities1.

Mechanical & Thermal Architecture LeadershipDefine 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 productsOwn thermal management strategy: Natural & forced air coolingLiquid cooling (cold plate, immersion where applicable)Heat exchanger and airflow optimizationDefine enclosure concepts, IP ratings, corrosion protection, and seismic/wind load compliance.2.

Product Engineering & ExecutionLead teams covering

Mechanical Design & CADPackaging & Industrial DesignThermal & CFD EngineeringStructural & Sheet-Metal DesignUnderstand and implement mechanical design standards, guidelines, and review processes.Drive power density improvements through optimized packaging.Ensure design trade-offs between cost, thermal performance, reliability, acoustics, and serviceability.3.

Product Development Lifecycle OwnershipOwn mechanical development across

Requirements → Concept → Detailed Design → Prototype → Validation → ProductionImplement V-Model / Stage-Gate / APQP processes.Drive Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Serviceability (DFS).Lead value engineering and cost-reduction initiatives.Prepare and maintain:3D models & 2D drawingsBOMs & assembly instructionsInstallation and service manualsEnsure proper revision and change management.4.

Thermal, Reliability & Environmental ValidationOwn thermal validation plans (steady-state, transient, derating analysis).Coordinate with CFD team - Given input simulations and correlation with physical testing.Select heatsinks, cooling methods that are manufacturalEnsure compliance with: Temperature rise limitsNoise & vibration requirementsEnvironmental tests (IP, salt mist, humidity, dust)

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.5. Integration with Electrical & Control SystemsCoordinate with electrical and control teams on: Component placement & clearancesCable routing and bending radiusEMI shielding & segregationEnsure creepage, clearance, and safety requirements are mechanically supported.6.

Manufacturing, Quality & Field SupportSupport NPI, pilot builds, and production ramp-up.Drive mechanical failure analysis, field issue RCA, and corrective actions.

Work with supply chain on: Vendor qualificationLocalization & alternate sourcingTooling and fixture developmentImprove yield, assembly time, and cost in production.7.

Cross-Functional & Business EngagementWork closely with: Electrical & Power Electronics EngineeringCFD/Thermal, Structural Analysis teamsSystems & ControlsManufacturing, Quality, and Supply ChainAct as mechanical authority in customer and certification discussions.Support pre-sales and customization efforts.Build and mentor a high-performance mechanical engineering organization.EducationBE / BTech in Mechanical EngineeringMTech / MS preferredExperience8+ years in mechanical engineering for power electronics or industrial productsProven leadership in high-power, thermally constrained systemsExperience from concept to mass production environmentsMechanical

Design, Thermal Engineering, Packaging & ValidationShould have handled team of mechanical designShould have experience in EV Charger OEMs and Industrial Power Electronics Companies.Technical CompetenciesThermal management of power electronicsSolidworks/AutoCADUnderstanding CFD tools (ANSYS, Flotherm, Icepak, etc.)Sheet metal, castings, plastics, and structural designEnclosure design (IP65/IP66/IP67)Shock, vibration, seismic & wind load analysisAcoustic noise reductionLeadership & Behavioural SkillsStrong system-level thinkingDecision-making under technical and cost constraintsPeople leadership & mentoringCross-functional collaborationContinuous improvement mindset

Qualifications

Bachelor of Technology (BTech)