Senior Engineer I, Electromechanics / Mechanical Design

Key Responsibilities

1. Product Mechanical Design:

a. Lead the overall structural, exterior, thermal, and protection design for new products.

b. Create 3D models, generate detailed 2D engineering drawings, and prepare all related structural design documentation.

c. Demonstrate expertise in designing plastic injection molding and sheet metal processes. Select appropriate materials to optimize design for cost, manufacturability, and performance.

2. Thermal Design & Optimization:

a. Take ownership of product thermal management solutions. This includes heatsink design and selection, fan/cooling duct design, and application of thermal interface materials.

b. Collaborate with thermal simulation engineers or directly use CFD software (e.g., FloTHERM, Icepak) to perform thermal analysis. Iterate and optimize the structural design based on simulation results to ensure power components operate within temperature limits under all conditions.

3. Safety & EMC Compliance Design:

a. Thoroughly understand and apply international safety standards (e.g., UL 1741, IEC 62109) to ensure designs meet requirements for creepage/clearance distances, flammability ratings, and grounding.

b. Work closely with electronics and EMC engineers to ensure product passes EMC tests through structural means, such as shielding and grounding strategies.

4. Prototyping & Testing Validation:

a. Lead the build and assembly of prototypes and first articles from molds. Troubleshoot and resolve structural issues during assembly.

b. Develop and execute structural validation test plans (e.g., vibration, shock, drop, thermal cycling, salt spray). Analyze test failures, identify root causes, and implement effective solutions.

5. Cross-functional Collaboration & Lifecycle Management:

a. Work effectively with Hardware, Software, ID (Industrial Design), Procurement, Quality, and Manufacturing teams to resolve issues throughout the product development cycle.

b. Support continuous improvement and cost reduction (VAVE) initiatives for mass-produced products.

Qualifications & Requirements

1. Education:

a. Bachelor's degree or higher in Mechanical Engineering, Mechatronics or related field.

2. Experience:

a. 5+ years of experience in mechanical design within the power electronics industry (e.g., PV inverters, energy storage systems, server/telecom power supplies, UPS, variable frequency drives).

b. Proven track record of independently designing and delivering structural systems for successfully mass-produced products.

3. Technical Skills:

a. CAD/CAE Tools: High proficiency in 3D CAD software (SolidWorks, CREO/Pro-E, or Siemens NX). Experience with FEA software (ANSYS, Abaqus) for structural and modal analysis is a plus.

b. Thermal Management: Must possess a solid foundation in thermal design. Hands-on experience with thermal simulation software (FloTHERM, Icepak) is highly desirable.

c. Standards & Compliance: Familiarity with relevant product safety, IP (Ingress Protection) ratings, and vibration standards.

d. Materials & Processes: Strong knowledge of common metal (sheet metal, aluminum extrusion/die-casting) and non-metal (plastics, insulating materials) properties and finishing processes.

4. Personal Attributes:

a. Strong analytical and problem-solving skills with keen attention to detail.

b. Excellent communication and teamwork skills, with the ability to thrive in a fast-paced, dynamic environment.

c. High sense of ownership and accountability for projects.

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