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 design
  • industrial PE products
• Own thermal management strategy:
  • Natural & forced air cooling
  • Liquid cooling (cold plate, immersion where applicable)
  • Heat exchanger and airflow optimization
• Define enclosure concepts, IP ratings, corrosion protection, and seismic/wind load compliance.

2. Product Engineering & Execution

• Lead teams covering:
  • Mechanical Design & CAD
  • Packaging & Industrial Design
  • Thermal & CFD Engineering
  • Structural & Sheet-Metal Design
• Understand 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 Ownership

• Own mechanical development across:
  • Requirements → Concept → Detailed Design → Prototype → Validation → Production
• Implement 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 drawings
  • BOMs & assembly instructions
  • Installation and service manuals
• Ensure proper revision and change management.

4. Thermal, Reliability & Environmental Validation

• Own 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 manufactural 
• Ensure compliance with:
  • Temperature rise limits
  • Noise & vibration requirements
  • Environmental tests (IP, salt mist, humidity, dust)
• Perform/Coordinate  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.

5. 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.

6. Manufacturing, Quality & Field Support

• Support NPI, pilot builds, and production ramp-up.
• Drive mechanical failure analysis, field issue RCA, and corrective actions.
• Work with supply chain on:
  • Vendor qualification
  • Localization & alternate sourcing
  • Tooling and fixture development
• Improve yield, assembly time, and cost in production.

7. Cross-Functional & Business Engagement

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

Education

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

Experience

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

Technical Competencies

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

Leadership & Behavioural Skills

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