Mechanical Design Engineer (Thermal Systems)

Roles & Responsibilities

• Design and develop thermal system components and assemblies for EV powertrain and battery packs (e.g., flexible thermal units, thermal paths, housings, heat sinks, and cooling structures) from concept to production.
• Translate electrical, thermal, and mechanical requirements into detailed subsystem specifications, stack-ups, and interface definitions for motors, inverters, battery packs, and associated cooling circuits.
• Perform thermal and structural simulations (FEA) to optimize temperature distribution, junction temperatures, and structural integrity, and drive design trade-offs based on performance, cost, and manufacturability.
• Collaborate with electrical, electronics, and systems teams to define thermal paths in multi-board power-electronics assemblies and motor systems, ensuring reliable operation under automotive environmental conditions.
• Execute detailed 3D modelling and 2D drawings for castings, sheet-metal, plastic, and machined parts, ensuring GDT, tolerance stack-up, and DFM/DFA compliance.
• Support validation and verification by defining load cases, test conditions, and acceptance criteria for thermal and environmental testing (e.g., IP, vibration, durability), and drive root cause analysis for failures.
• Manage BOMs, configuration, and change control in PLM tools, and coordinate with suppliers and manufacturing for tooling, feasibility, and industrialization.

Preferred candidate profile

• Bachelor's degree in mechanical engineering or related discipline.
• 58 years of experience in mechanical design with strong exposure to thermal systems for EV powertrain, battery packs, power electronics, or similar high-reliability domains.
• Hands-on experience with 3D CAD (Creo, NX, CATIA, SolidWorks or equivalent) for complex electromechanical assemblies and enclosure systems.
• Proven experience in structural and thermal analysis using tools such as ANSYS Workbench or equivalent, including interpretation of results and design iteration.
• Strong knowledge of GDT, tolerance stack-up, and design for manufacturing for injection molding, sheet metal, die casting, and machined components.
• Experience in designing motor-related mechanical parts or thermal hardware for EV or automotive applications is highly desirable.
• Experience with EV thermal management solutions such as integrated thermal units, cooling plates, heat sinks, and IP-rated power-electronics or battery enclosures.
• Familiarity with DFMEA/DRBFM, system-level requirement management, and cross-functional design reviews in automotive or defense-grade environments.
• Working knowledge of PLM tools such as Teamcenter, Windchill, or SAP for configuration and release management.