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

• 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
• Drive platform reuse, modularization, and standardization
• Align with global product roadmaps and customer-specific adaptations
• Thermal & Cooling Engineering (Critical for Tier-1)
• Design high-efficiency cooling systems:
• Forced air cooling (ducted, sealed systems)
• Liquid cooling (cold plates, manifolds, CDU integration)
• Perform Multiphysics simulations using:
• ANSYS
• Icepack
• FloTHERM
• Optimize junction temperatures for IGBT / SiC devices, magnetics, and capacitors
• Ensure derating strategy and thermal robustness under worst-case conditions
• Mechanical Design & CAD Ownership
• Lead detailed design using:
• Creo
• Siemens NX
• SolidWorks
• Develop:
• 3D CAD models, assemblies, and 2D drawings
• GD&T, tolerance stack-ups, and design release packages
• Manage BOM and interface with PLM systems
• Design for Excellence (DFX) – Tier-1 Focus
• Drive:
• DFM (Manufacturability)
• DFA (Assembly)
• DFC (Cost optimization)
• DFS (Serviceability)
• Collaborate with global suppliers and contract manufacturers
• Support sourcing strategy and vendor development
• Reliability, Durability & Validation
• Design for automotive/industrial reliability targets (10–15+ years life)
• Conduct and support:
• HALT / HASS
• Thermal cycling
• Vibration & mechanical shock tests
• IP ingress protection validation
• Perform FEA (structural, vibration, fatigue)
• Compliance & Safety (Mandatory Tier-1 Exposure)
• Ensure compliance with:
• IEC / UL / ISO standards
• Environmental & enclosure standards (IP54–IP66)
• Work with safety teams on:
• Functional safety (alignment with ISO 26262 principles where applicable)
• Creepage & clearance coordination with electrical design
• Support certification and regulatory audits
• Cross-Functional Leadership
• Lead collaboration with:
• Power electronics and electrical teams
• Controls & firmware teams
• Manufacturing, quality, and sourcing teams
• Interface directly with customers (OEMs, utilities, EPCs)
• Drive design reviews, DFMEA, and risk mitigation
• Program Execution & Ownership
• Own product lifecycle from:
• Concept → Prototype → Validation → SOP → Mass production
• Support APQP processes:
• DFMEA / PFMEA
• PPAP documentation
• Ensure on-time delivery aligned with program milestones
  

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

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

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

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

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

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

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