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
- Strong 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 (Bengaluru)
🏢 Ford
📍 Bengaluru