As a Sr Mechanical Engineer, you will be working on our next-generation Power Electronics Modules from initial concept through to full-scale production. You will be responsible for designing critical components including Busbars, metal housings, sealing interfaces, and HV/LV harnesses, Plastic Injection molded parts from the ground up. This role requires close collaboration with cross-functional teams to resolve complex packaging challenges.
This position is based at our Carson, CA facility and reports directly to the Sr. Mechanical Engineering Manager.
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Lead the mechanical development of Power Electronics Modules using CATIA V6/3DEXPERIENCE
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Design and engineer a wide array of components, including high-pressure die castings, injection-molded plastics, busbars, sheet metal, high/low voltage harnesses, sealing interfaces, and PCBA mechanical integration
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Manage the full release cycle of mechanical components using ENOVIA, ensuring data integrity and design maturity
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Generate and maintain complex Top-Level Assembly Bills of Materials (BOM), ensuring all component attributes are captured with 100% accuracy
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Drive weekly technical reviews with suppliers to close open design items, manage timelines, and ensure DFM (Design for Manufacturing) alignment
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Act as the primary technical liaison for Supply Chain and Supplier Quality teams to resolve action items and maintain production schedules
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Author critical engineering documents, including Component Technical Specifications (CTS), Statements of Work (SOW) for sourcing, and detailed assembly manuals
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Collaborate with Systems team on DFMEAs and develop robust Design Verification (DV) test plans to ensure long-term product reliabilit
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Provide on-site support for pre-production lines, including the design of specialized mechanical test fixtures and assembly aids
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Collaborate closely with Manufacturing Engineering to design, validate, and commission the production line on schedule
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Lead troubleshooting efforts for issues arising during prototype builds and scale-up
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Spearhead the root cause investigation of field failures related to mechanical assemblies, implementing design improvements to prevent recurrence
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Bachelor’s degree in mechanical engineering or a related engineering discipline
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4+ years of engineering experience, specifically in the development and packaging of Power Electronics assemblies
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Expert-level proficiency in CATIA V5 or V6 (3DEXPERIENCE), specifically within Part Design and Assembly Design workbenches
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Proven track record designing for diverse processes, including high-pressure die casting, injection molding, and sheet metal fabrication
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Deep experience in the design of high-voltage busbars, HV/LV wire harnesses, and sealing/gasket systems
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Practical knowledge of integrating components using laser welding, press-fit, soldering, heat staking and thermal interface materials (TIM)
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High proficiency in GD&T (ASME Y14.5) and experience developing DFMEA documents and system-level validation plans (Mechanical, Electrical, and Thermal)
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Working knowledge of the ENOVIA Product Lifecycle Management environment
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Extensive experience managing external technical suppliers, ensuring quality and timeline adherence
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Demonstrated ability to use structured root-cause analysis techniques to identify and resolve complex component failures
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General knowledge of mechanical best practices for PCBA design and integration
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Prior experience in the Automotive industry (Tier 1 or OEM)
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Thrives in a fast-paced startup environment
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Proficiency with Microsoft Project, Visio, and the standard Office suite
