Senior Mechanical Engineer - Sustaining

Position Summary

Responsible for sustaining the mechanical design of existing switch mode power supply products, with primary emphasis on end-of-life and obsolescence issues, material shortages, qualification of alternative mechanical parts and materials, failure analysis, implementation of approved engineering changes, and supplier-driven changes.

Duties & Responsibilities

• Provide mechanical sustaining engineering support for existing power supply products, primarily addressing material shortages, end-of-life or obsolescence, supplier changes, and internal mechanical quality or reliability issues.
• Evaluate alternative mechanical parts and chemical materials proposed by suppliers or component engineering team, including enclosures, chassis, covers, brackets, heatsinks, fans, thermal interface materials, plastics, sheet-metal parts, cast parts, machined parts, cables, connectors, gaskets, adhesives, potting materials, insulation, labels, fasteners, packaging, and PCB mechanical integration, etc.
• Support occasional mechanical aspects of transformers, inductors, magnet wires and other magnetic components in collaboration with electrical or component engineering.
• Review supplier drawings, specifications, samples, and technical proposals; assess fit, form, function, tolerance, material, thermal performance, manufacturability, quality, and reliability.
• Modify existing 3D models, assemblies, and 2D engineering drawings using appropriate mechanical CAD tools to implement sustaining design changes.
• Own the technical change from assessment through implementation, including mechanical risk assessment, prototype or sample review, qualification planning, design updates, and technical support for ECO/ECN implementation.
• Develop validation plans, coordinate or conduct mechanical tests, analyse results, document conclusions, and make technical decisions on alternatives and sustaining changes.
• Perform practical thermal assessments involving temperature measurements, heatsinks, fans, airflow, thermal interface materials, and validation of alternative parts or materials.
• Independently support mechanical failure investigations, including evidence collection, root-cause analysis, testing, validation, corrective actions, and technical documentation.
• Work closely with sourcing, quality, manufacturing, electrical engineering, and suppliers to resolve supplier-related technical issues. Provide manufacturing support mainly when issues arise from shortages, obsolescence, or alternative-material implementation.

Qualifications

• Bachelor's degree or above in Mechanical Engineering, Mechatronics Engineering, or an equivalent engineering discipline.
• Minimum 7 years of experience in mechanical design or sustaining engineering. Experience in the power supply industry preferred but candidates with relevant experience in comparable electronic products will also be considered.
• Proven experience supporting existing products through mechanical changes driven by material shortages, end-of-life or obsolescence, supplier changes, and quality or reliability issues.
• Proficient in SolidWorks and AutoCAD, with hands-on experience modifying 3D models, mechanical assemblies, and 2D engineering drawings.
• Strong knowledge of mechanical design principles, including tolerance, fit, form and function, material selection, manufacturing processes, and DFM/DFA considerations.
• Practical experience evaluating and qualifying mechanical parts and materials, reviewing supplier drawings and samples, and assessing supplier technical proposals.
• Proven experience in mechanical testing, failure analysis, troubleshooting, root-cause analysis, corrective actions, and validation documentation.
• Experience with practical thermal assessment, including temperature measurement, heatsink and fan evaluation, airflow review, thermal interface material selection, and thermal validation.
• Working knowledge of switch mode power supply architecture and mechanical-electrical interactions, including PCB integration, thermal paths, magnetic components, creepage and clearance, and EMI/EMC considerations.
• Experienced in engineering change management processes, including design updates and technical support for ECO/ECN implementation.
• General awareness of applicable mechanical safety, environmental, material, and product compliance requirements, with detailed assessment supported by compliance specialists.
• Proficient in English.
• Familiar with Microsoft 365 applications, including Excel, PowerPoint, Teams, and SharePoint.