Mechanical Design Engineer

Location: Viman Nagar, Pune

Department: Mechanical Design / Product Engineering

Employment Type: Full-Time.

Position Overview

We are seeking a Mechanical Design Engineer with strong first-principles design ability, capable of taking a product from concept to validated hardware. This is a design origination role, not a drafting role. The candidate is expected to generate original mechanical concepts, substantiate them with independent engineering calculations, and carry them through detailing, prototyping, and qualification.

The role spans two areas. The first is enclosures, cabinets, chassis, and thermal and structural design for power electronic and embedded systems including rectifiers, inverters, UPS, SMPS, and power converters. The second is sealed portable and handheld product housings, including handles, control units, and battery compartments, requiring surface modelling, ergonomic form development, and ingress protection. Both industrial and ruggedized or defence-grade applications are covered. The candidate will work closely with hardware, PCB design, manufacturing, quality, and project teams.

Key Responsibilities

- Develop original mechanical concepts for new products from customer specifications, functional requirements, and system-level constraints.
- Design enclosures, cabinets, racks, sheet metal chassis, panels, mounting arrangements, and mechanical assemblies for electronic and power electronic equipment.
- Perform independent design calculations covering thermal load, heat sink sizing, airflow and fan selection, structural strength, deflection, weight, fastener and bolted joint sizing, centre of gravity, lifting and handling, and tolerance stack-up.
- Carry out thermal management design for high heat-dissipation assemblies using natural convection, forced air, conduction, and heat sink or cold plate solutions.
- Analyse and design for shock, vibration, and transportation loads, including natural frequency estimation and mounting or isolation schemes for ruggedized equipment.
- Design sealed portable and handheld housings control units, and battery compartments, qualified to IP ratings as required.
- Develop the complete sealing scheme for such products, covering gasket and O-ring groove design, compression and compression set, sealed connectors, cable glands, membrane keypads, display windows, potting, adhesive or ultrasonic welded joints, and pressure-equalisation vent membranes.
- Create complex freeform and surfaced geometry for ergonomic and cosmetically finished housings, controlling surface continuity, draft, parting lines, split-line aesthetics, texture, and cosmetic finish.
- Design injection-moulded plastic parts including material selection, wall thickness, ribs, bosses, snap fits, living hinges, inserts, and overmoulded grips, and work with tool makers through DFM review, tooling, and T0 and T1 trials.
- Address ergonomics, weight, balance, grip,



and single-handed operation for field-carried and handheld equipment.
- Produce complete 3D models, detailed manufacturing drawings with correct GD&T;, sheet metal development, Bills of Materials, and hardware and finish specifications.
- Perform FEA and CFD or thermal simulation to validate designs, and correlate simulation results with physical test data.
- Design for manufacturability and cost, working with sheet metal fabrication, machining, casting, extrusion, powder coating, and plating processes.
- Ensure mechanical design meets ingress protection, creepage and clearance, EMI shielding, earthing and bonding, serviceability, and cable routing requirements.
- Build and evaluate prototypes, resolve fitment and assembly issues on the shop floor, and drive design changes to closure.
- Support environmental, vibration, shock, drop and impact, ingress protection, and safety qualification testing, and address non-conformances arising from it.
- Interface with vendors and suppliers on fabrication feasibility, tooling, sampling, and first-article inspection.
- Prepare design documentation, calculation sheets, design review records, test reports, and product release documentation.
- Provide technical guidance to junior engineers and contribute to design standardisation and product innovation.
- Support prototype development, testing, troubleshooting, root-cause analysis, and design validation.
- Collaborate with fabrication vendors, machine shops, and manufacturing teams during development and production.
- Work with electrical, electronics, firmware, and software teams for product integration.

Qualifications and Experience

- M.E. / M.Tech in Mechanical Engineering, Design Engineering, or a related discipline.
- 5 to 12 years of relevant experience in mechanical product design, preferably for electronic, power electronic, electrical, or ruggedized equipment.
- Demonstrated record of designing new products, not only modifying or detailing existing designs. Candidates should be prepared to discuss designs they personally originated.
- Ability to carry out thermal, structural, and mechanical design calculations independently, and to defend the assumptions behind them in a design review.
- Robust command of 3D CAD (SolidWorks, Creo, Inventor, or NX) including sheet metal, weldments, large assemblies, and drawing generation.
- Hands-on advanced surface modelling capability, such as SolidWorks Surfacing, Creo Style or ISDX, NX Shape Studio, Rhino, or Alias,



with the ability to build and control multi-surface freeform geometry rather than prismatic and sheet metal features alone.
- Demonstrated experience delivering sealed housings qualified to IP ratings, including the sealing scheme, gasket and groove design, and resolution of leakage failures found in testing.
- Plastic part design and injection moulding experience, including material selection, DFM, tool feasibility discussion with mould makers, and correction of defects such as sink, warpage, weld lines, and short shots.
- Working knowledge of FEA and thermal or CFD simulation tools such as ANSYS, SolidWorks Simulation, Icepak, or Flotherm.
- Sound understanding of engineering materials, heat transfer, strength of materials, vibration, GD&T;, tolerance analysis, and manufacturing processes.
- Familiarity with applicable standards for enclosures and ruggedized equipment, such as IEC 60529 ingress protection, IEC 62262 IK impact ratings, MIL-STD-810, MIL-STD-461 mechanical and shielding aspects, and JSS 55555, will be an added advantage.
- Strong analytical ability, ownership, communication skills, and willingness to work hands-on with prototypes and on the shop floor.

Added Advantage

The following are not essential requirements, but will be considered favourably:

- Exposure to the design of fuzes, mechanical safety and arming devices, or other precision electro-mechanical armament sub-systems.
- Familiarity with fuze safety design criteria and qualification standards such as MIL-STD-1316, STANAG 4187, and MIL-STD-331, and with fuze safety review, certification, and clearance processes.
- Experience in precision small-mechanism design, including escapements, spring-mass systems, rotors, sliders, detents, ball locks, and inertially or centrifugally responsive elements.
- Experience designing mechanisms that must survive severe launch, setback, spin, and impact environments, supported by explicit dynamic finite element analysis.
- Experience designing for long-term storage without maintenance, including spring stress relaxation, elastomer ageing, dissimilar metal corrosion, and lubricant-free mechanism design.
- Exposure to air gun, centrifuge, jolt, jumble, and drop testing of armament or precision mechanical sub-systems.
- Experience preparing hazard analyses, FMEA, fault trees, and safety documentation for review by certification or safety authorities.

Interested candidates may apply with their updated rsum along with details of mechanical designs they have personally originated, including the design calculations, analysis, and validation carried out for them. Candidates are encouraged to include examples of both fabricated or sheet metal enclosure work and surfaced or moulded housing work where available.

Disclaimer

This job description is provided for reference purposes only. The roles, responsibilities, and scope of work may vary at the time of appointment based on organizational requirements and project assignments.

📌 Mechanical Design Engineer (Pune)
🏢 Precision Power Products
📍 Pune