Lead Mechanical Design Engineer – Power Converters
Role Summary
As a Lead Mechanical Design Engineer, you will own the end-to-end mechanical design and industrialization of high-power converter products (40 kW rectifier modules to MW-scale central inverters). The role requires deep expertise in automotive-grade design processes, reliability engineering, and global compliance standards, ensuring scalable, cost-optimized, and production-ready solutions.
Key Responsibilities
Product Architecture & Platform Strategy
Define scalable mechanical platforms for:
Rectifier modules (30–60 kW class)
Power stacks and converter cabinets
MW-scale central inverter systems
Drive platform reuse, modularization, and standardization
Align with global product roadmaps and customer-specific adaptations
Thermal & Cooling Engineering (Critical for Tier-1)
Design high-efficiency cooling systems:
Forced air cooling (ducted, sealed systems)
Liquid cooling (cold plates, manifolds, CDU integration)
Perform Multiphysics simulations using:
ANSYS
Icepack
FloTHERM
Optimize junction temperatures for IGBT / SiC devices, magnetics, and capacitors
Ensure derating strategy and thermal robustness under worst-case conditions
Mechanical Design & CAD Ownership
Lead detailed design using:
Creo
Siemens NX
SolidWorks
Develop:
3D CAD models, assemblies, and 2D drawings
GD&T;, tolerance stack-ups, and design release packages
Manage BOM and interface with PLM systems
Design for Excellence (DFX) – Tier-1 Focus
Drive:
DFM (Manufacturability)
DFA (Assembly)
DFC (Cost optimization)
DFS (Serviceability)
Collaborate with global suppliers and contract manufacturers
Support sourcing strategy and vendor development
Reliability, Durability & Validation
Design for automotive/industrial reliability targets (10–15+ years life)
Conduct and support:
HALT / HASS
Thermal cycling
Vibration & mechanical shock tests
IP ingress protection validation
Perform FEA (structural, vibration, fatigue)
Compliance & Safety (Mandatory Tier-1