Principal Mechanical Engineer

Hewlett Packard Enterprise•Sunnyvale, CA

5d•$140,500 - $285,000•Onsite

About The Position

The Principal Mechanical Engineer is a hands-on individual contributor who reports to the Head of Mechanical Engineering and leads mechanical design, structural analysis, development, and qualification of complex networking systems from concept through production. The role involves independently solving challenging engineering problems and collaborating with cross-functional teams in a fast-paced product development environment. The engineer develops and maintains structural FEA capabilities, improves simulation accuracy through test correlation, and supports new product introduction (NPI) and sustaining engineering. The position includes mechanical design, prototype evaluation, laboratory testing, root-cause investigations, and design improvements to ensure product reliability and structural integrity. The engineer serves as a key contact for mechanical issues arising during MDVT and HALT, validates design changes through simulation and testing, and communicates recommendations to hardware leads. The role also supports chassis and fixture design, strain-gauge and accelerometer measurements, test-data analysis, system packaging, reliability, manufacturability, manufacturing yield improvement, and collaboration with suppliers, ODMs, ASIC teams, and other engineering functions. The position is onsite, primarily at an HPE office.

Requirements

At least 10 years of experience in electromechanical product development.
Master’s degree in Mechanical Engineering, Applied Physics, or equivalent.
Experience developing networking, server, storage, telecommunications, or high-performance computing systems.
Extensive experience with chassis development, system packaging, and high-density electronic assemblies.
Experience with FEA and familiarity with ANSYS Workbench, including static-structural, modal analysis, transient mode superposition, Eigenvalue-Buckling, and steady-state thermal analysis.
Strong hands-on experience with tolerance analysis, GD&T, stack-up analysis, and structural analysis techniques.
Experience meshing sheet-metal geometries as solid or shell elements and defeaturing non-structural elements to simplify meshes.
Strong structural intuition regarding load paths in mechanical designs.
Ability to break complex system designs into subsystems to simplify FEA setup and runtime.
Familiarity with test standards including GR-63, IPC-9704, and ASTM D4169.
Working knowledge of Young’s modulus and coefficients of thermal expansion of common materials used in ASIC and cooling components.
Experience with accelerometer G-value data filtering and analysis from dynamic tests such as vibration and shock.
Hands-on experience in dynamic testing.
Extensive experience developing complex chassis and system-level mechanical designs for networking, server, storage, or telecommunications products.
Experience with ECAD-MCAD integration and IDF workflows.
Understanding of sheet-metal design, machining, castings, extrusions, plastics, and associated manufacturing processes.
Understanding of tooling requirements and manufacturing considerations for volume production.
Understanding of NEBS, EMI, EMC, safety, and other regulatory compliance requirements.
Ability to troubleshoot complex system-level mechanical issues in laboratory, manufacturing, and field environments.
Experience leading root-cause investigations and implementing corrective actions.
Excellent communication and leadership skills, including the ability to influence cross-functional teams.
Comprehensive understanding of the product development lifecycle from concept through production and field support.

Nice To Haves

SolidWorks experience; working knowledge of EPDM or an equivalent PLM system is a plus.
Experience with LS-Dyna and response spectrum analysis.
Experience modeling die warpage due to thermal effects and heatsink loading.
Training in PCB strain-gauge applications and data analysis involving principal microstrain and strain rate.
Knowledge of dye-and-pry, Shadowmoire, and operation of 3D-scanning metrology equipment.

Responsibilities

Develop and own structural FEA simulation capabilities for ongoing NPI projects and sustaining issues.
Improve simulation accuracy through test correlation and model refinement.
Maintain and coordinate multiple FEA projects involving internal functions and external partners.
Drive and review FEA simulation efforts conducted by component suppliers and ODMs.
Provide design guidance from the concept phase by running FEA studies on areas of concern.
Serve as the main point of contact for mechanical issues arising from MDVT and HALT, and lead resolution by validating design changes through simulation and/or testing.
Design and prototype chassis and fixtures for testing.
Develop in-house expertise in strain-gauge applications and accelerometer measurements during MDVT and HALT.
Process and analyze test data, including microstrain, G-levels, and ASIC temperatures, throughout MDVT and HALT.
Document tests and FEA simulations, including static loading, modal analysis, and dynamic analysis, in NPI design reviews, and take responsibility for system structural integrity.
Communicate recommended design changes to hardware leads with justification supported by FEA results.
Collaborate with the ASIC development team to create 3D ASIC models from package outline drawings, including BGAs, and conduct near-package or co-package connector placement and floorplan studies as needed.
Support manufacturing and operations in improving production yield through FEA studies or limited laboratory design-of-experiments work.
Provide mechanical design and structural analysis support across product development programs, including chassis design, packaging, reliability, and manufacturability.
Participate in hands-on engineering activities, including CAD design and reviews, tolerance analysis, prototyping, testing, and root-cause investigations.
Collaborate with cross-functional teams and suppliers to identify technical risks, resolve design and manufacturing issues, and implement corrective actions.
Contribute to mechanical specifications, design guidelines, validation plans, and engineering best practices.
Provide project scoping, resource estimates, schedule input, and technical guidance for new product development efforts.