Mechanical Engineer

Required Skills & Experience

• Bachelor's or Master's degree in Mechanical Engineering or a related technical field.
• 10+ years of industry experience in mechanical design and product packaging for power electronics, industrial, or energy products.
• Advanced proficiency with 3D CAD software such as CATIA V5/V6, SolidWorks, NX, Creo, or 3DEXPERIENCE.
• Strong theoretical and practical understanding of structural mechanics, dynamics, heat transfer, and materials.
• Experience with structural, thermal, and vibration analysis using commercial simulation software such as Ansys or Comsol.
• Experience designing for manufacturing processes including injection molding, die casting, extrusion, and sheet-metal forming.
• Working knowledge of engineering materials including aluminum, steel, engineering plastics, ceramics, structural insulators, gaskets, and potting compounds.
• Hands-on experience taking complex electro-mechanical designs from concept through prototyping, supplier tooling, pilot builds, and high-volume production.
• Familiarity with documentation, testing, and design integration associated with regulatory standards such as UL, IEC, NFPA, and ISO.
• Strong technical communication and cross-functional collaboration skills.

Nice to Have Skills & Experience

• PhD in Mechanical Engineering.
• Proficiency with PLM platforms such as 3DEXPERIENCE or Windchill for configuration management, CAD assemblies, BOMs, and manufacturing releases.
• Experience with medium- to high-voltage equipment and insulation coordination, including creepage, clearance, potting, and sealing.

Job Description

Insight Global is seeking an experienced Mechanical Engineer for a client developing advanced high-power energy and power-conversion systems. This engineer will join a multidisciplinary team responsible for the mechanical packaging, structural design, thermal-fluid management, and production release of high-power, grid-connected power conversion equipment supporting utility-scale energy storage, data center, and industrial electrification applications. The role requires technical depth in structural mechanics, heat transfer, thermal management, and physical packaging architectures. This individual will contribute throughout the electro-mechanical product lifecycle, from early architectural trade studies and detailed thermal/structural analysis through prototype development, validation, regulatory compliance, and production. The Mechanical Engineer will work closely with electrical, controls, compliance, reliability, manufacturing, and supplier teams to translate complex electro-mechanical designs into robust, production-ready hardware.

Key Responsibilities

• Mechanical Architecture & Enclosure Design: Lead physical packaging and structural design for multi-megawatt industrial cabinets and utility enclosures, including IP-rated and outdoor-rated equipment. Conduct trade studies involving architecture, materials, design, and manufacturing processes.
• Thermal Management & Multi-Physics Analysis: Design and analyze thermal-management systems using forced-air and liquid cooling, including cold plates, thermal interface materials, and optimized airflow paths. Perform or support structural FEA, thermal CFD, vibration, and fatigue assessments.
• Electro-Mechanical Integration: Package high-density electronic assemblies, PCBA interfaces, custom magnetic components, insulators, heavy-duty busbars, and high-voltage/high-current connectors while balancing mechanical, isolation, and EMI/EMC requirements.
• CAD, Drawings & PLM Releases: Create detailed 3D CAD models and production-ready 2D drawings using GD&T. Conduct tolerance stack-up analyses and support BOMs, engineering documentation, and ECOs within PLM systems.
• FMEA & Validation: Participate in mechanical Failure Mode and Effects Analysis (FMEA) and Design Verification Plan and Report (DVP&R) activities.
• Prototype & Lab Testing: Support physical prototype fabrication, electro-mechanical assembly, custom test-rig setup, and hands-on mechanical testing. Support root-cause analysis of pilot and production failures and resulting hardware revisions.
• DFM/DFA & Production Scaling: Partner with quality, manufacturing, and external suppliers on Design for Manufacturability (DFM), Design for Assembly (DFA), assembly processes, tooling strategies, and work instructions supporting scalable production.