As a Lead Mechanical Engineer, you will be part of Fords Global Advanced Product Development team, working on critical systems such as onboard chargers, DC/DC converters, battery management systems, and motor controllers. You will collaborate with cross-functional teams to design, prototype, validate, and deliver mechanical solutions for high-voltage power electronics in electric vehicles.

This role offers the chance to work on cutting-edge technologies and influence designs that reach global production.
Design and develop mechanical components and assemblies for EV power electronics systems, ensuring performance, cost, and reliability targets are met
Collaborate with electrical, manufacturing, testing, and quality teams to ensure design-for-excellence (manufacturability, reliability, serviceability)
Develop and validate prototypes using rapid prototyping techniques
Work closely with suppliers from concept to production to ensure material and process feasibility
Support product validation through test planning, execution, and documentation
Identify and resolve manufacturing and quality issues using structured problem-solving methods (e.g., FMEA,



root cause analysis)
Support development of assembly processes and test fixtures
Review engineering simulations (FEA) and incorporate improvements into designs
Mentor junior engineers and contribute to technical reviews

Must-Have
Bachelors degree in Mechanical Engineering or related field
8+ years of experience in electromechanical product design for high-volume manufacturing
Solid understanding of:
GD&T; (Geometric Dimensioning & Tolerancing)
Tolerance stack-up analysis
Design for manufacturing (DFM) across casting, machining, and plastics
Plastic product design expertise
Experience with PLM tools (e.g., Teamcenter or similar)
Proficiency with CAD tools such as CATIA V6 / 3DEXPERIENCE
Experience in prototyping, testing, and production release

Nice-to-Have
Masters degree or certification in tool design (e.g., GTTC, NTTF)
Experience in high-voltage electronics packaging
Experience in EV systems (OBC, DC/DC converters, EV charging systems)
Experience working with global suppliers

📌 Lead Mechanical Engineer Karnataka
🏢 Ford
📍 Karnataka