Lead Mechanical Design Engineer - Power Converters

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 
• Drive platform reuse, modularization, and standardization 
• Align with global product roadmaps and customer-specific adaptations 

2. 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 

3. 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 

4. 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 

5. 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) 

6. 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 

7. 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 

8. 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 

Required Qualifications

• 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) 

Core Competencies 

Technical Depth

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

Process Excellence

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

Domain Knowledge

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

Preferred Experience

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

Leadership Expectations

• 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 

KPIs / Success Metrics

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

On-time SOP delivery