Senior Mechanical Engineer – Power Electronics & High-Voltage Systems

We are seeking an experienced Mechanical Engineer specializing in power electronics and high-voltage systems to design, develop, and optimize high-voltage electrical distribution components and electromechanical enclosures. The ideal candidate will have hands-on experience with busbars, electrical connectors, thermal analysis, and sheet metal enclosure design, along with strong proficiency in SolidWorks.

This role involves taking designs from initial concept through prototyping, validation, and mass production while collaborating with multidisciplinary engineering teams to ensure safety, reliability, manufacturability, and performance.

What You’ll Do

• Design and develop high-voltage power distribution systems, including busbars, cables, connectors, electrical joints, grounding, isolation, fuses, contactors, and interlocks.
• Design and optimize electromechanical assemblies, including metal and plastic enclosures, large sheet metal components, and packaging for electrical and PCBA assemblies.
• Perform thermal, structural, and electrical design calculations, including resistive losses, current density, and busbar sizing and optimization.
• Evaluate creepage and clearance requirements, electrical insulation, grounding, sealing, and thermal management to ensure product safety and reliability.
• Develop and optimize bolted and welded electrical joints while addressing shock, vibration, and harsh-environment requirements.
• Create 3D CAD models, 2D engineering drawings, GD&T documentation, and manufacturing instructions using SolidWorks.
• Lead design activities from concept development through prototyping, testing, design validation, and mass production.
• Collaborate with electrical, manufacturing, testing, and cross-functional engineering teams to resolve technical issues and conduct root cause analysis (RCA).
• Apply design for manufacturing and assembly (DFM/DFA) principles to improve product quality, manufacturability, cost, and reliability.
• Support the design and development of electromechanical systems for test stands, including safety improvements and design simplification.

What You’ll Bring

• Bachelor’s degree in Mechanical Engineering, Mechatronics Engineering, or a related field, with approximately 6+ years of relevant experience; candidates with a master’s degree and 4+ years of relevant experience may also be considered.
• Hands-on experience in power electronics mechanical design, high-voltage systems, electrical power distribution, busbars, connectors, and electromechanical assemblies.
• Strong proficiency in SolidWorks; experience with CATIA or other 3D CAD tools is a plus.
• Experience designing high-power electrical components and large sheet metal or metal enclosures, including packaging, thermal management, electrical isolation, and grounding.
• Strong understanding of mechanical and electrical engineering fundamentals, first-principles hand calculations, thermal analysis, GD&T, DFM/DFA, and manufacturing processes.
• Knowledge of creepage and clearance requirements, electrical safety standards such as IEC and UL, and busbar optimization, including resistive losses and current density analysis.

Preferred Qualifications

• Experience with power electronics systems used in industrial, utility, energy storage, or other high-power applications.
• Familiarity with thermal simulation, CFD, structural analysis, and cost optimization.
• Experience taking products from initial concept through prototyping, validation, and production.
• Experience with root cause analysis, cross-functional design reviews, and technical problem-solving.

Interview Process