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
