Mechanical Design Engineer

Tech Lead -Mechanical Design | Power Electronics Product & Systems (P11b) Role Provide end-to-end leadership for mechanical engineering of power electronics products and integrated systems, ensuring robust mechanical architecture, effective thermal management, environmental protection, manufacturability, and lifecycle reliability across high-power, high-density electrical platforms (AC-DC/DC-DC Converters, EV Chargers and Industrial Power Electronics products.) Key Responsibilities Mechanical & Thermal Architecture Leadership Define mechanical system architecture for: High Voltage EV Chargers (AC, DC Fast, Ultra-Fast) Solar Inverters (String & Central) Automotive On-board Chargers/ Drivetrain inverter /MCU enclosure design industrial PE products Own thermal management strategy: Natural & forced air cooling Liquid cooling (cold plate, immersion where applicable) Heat exchanger and airflow optimization Define enclosure concepts, IP ratings, corrosion protection, and seismic/wind load compliance. Product Engineering & Execution Lead teams covering: Mechanical Design & CAD Packaging & Industrial Design Thermal & CFD Engineering Structural & Sheet-Metal Design Understand and implement mechanical design standards, guidelines, and review processes. Drive power density improvements through optimized packaging. Ensure design trade-offs between cost, thermal performance, reliability, acoustics, and serviceability. Product Development Lifecycle Ownership Own mechanical development across: Requirements Concept Detailed Design Prototype Validation Production Implement V-Model / Stage-Gate / APQP processes. Drive Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Serviceability (DFS). Lead value engineering and cost-reduction initiatives. Prepare and maintain: 3D models & 2D drawings BOMs & assembly instructions Installation and service manuals Ensure proper revision and change management. Thermal, Reliability & Environmental Validation Own thermal validation plans (steady-state, transient, derating analysis). Coordinate with CFD team - Given input simulations and correlation with physical testing. Select heatsinks, cooling methods that are manufactural Ensure compliance with: Temperature rise limits Noise & vibration requirements Environmental tests (IP, salt mist, humidity, dust) Perform/Coordinate structural analysis for: Static & dynamic loads Transportation & seismic conditions Ensure compliance with wind, seismic, and shock/vibration requirements. Design for safe lifting, handling, and installation. Integration with Electrical & Control Systems Coordinate with electrical and control teams on: Component placement & clearances Cable routing and bending radius EMI shielding & segregation Ensure creepage, clearance, and safety requirements are mechanically supported. Manufacturing, Quality & Field Support Support NPI, pilot builds, and production ramp-up. Drive mechanical failure analysis, field issue RCA, and corrective actions. Work with supply chain on: Vendor qualification Localization & alternate sourcing Tooling and fixture development Improve yield, assembly time, and cost in production. Cross-Functional & Business Engagement Work closely with: Electrical & Power Electronics Engineering CFD/Thermal, Structural Analysis teams Systems & Controls Manufacturing, Quality, and Supply Chain Act as mechanical authority in customer and certification discussions. Support pre-sales and customization efforts. Build and mentor a high-performance mechanical engineering organization. Education BE / BTech in Mechanical Engineering MTech / MS preferred Experience 8+ years in mechanical engineering for power electronics or industrial products Proven leadership in high-power, thermally constrained systems Experience from concept to mass production environments Mechanical Design, Thermal Engineering, Packaging & Validation Should have handled team of mechanical design Should have experience in EV Charger OEMs and Industrial Power Electronics Companies. Technical Competencies Thermal management of power electronics Solidworks/AutoCAD Understanding CFD tools (ANSYS, Flotherm, Icepak, etc.) Sheet metal, castings, plastics, and structural design Enclosure design (IP65/IP66/IP67) Shock, vibration, seismic & wind load analysis Acoustic noise reduction Leadership & Behavioural Skills Strong system-level thinking Decision-making under technical and cost constraints People leadership & mentoring Cross-functional collaboration Continuous improvement mindset