Senior Mechanical Design Engineer - Power Systems

Lightship • Broomfield, CO

21h • $100,000 - $130,000 • Hybrid

About The Position

As a Senior Mechanical Design Engineer you will serve as a hands on technical lead for multiple power systems sub-systems, primarily our all-electric RV’s Solar System. You will be responsible for continuing developing, prototyping, and testing of the solar arrays, related junction boxes, harnessing, charge controllers and circuit protection. With a small team, you'll also help dive into development on other Power Systems components, including power distribution modules, mounting brackets, electronics enclosures, and selecting off the shelf electronics components

Requirements

• 5+ years design engineering experience
• Comfortable working in a dynamic environment with shifting priorities and needs
• Able to adapt quickly to change and approach challenges with flexibility and creativity
• Solutions-oriented, with a focus on progress and impact over perfection
• Willingness to operate effectively at both strategic and hands-on levels (contributing as an individual contributor and leading as a manager)
• Expertise with a majority of the following:
• CAD/PLM/PDM systems
• Creating detailed 3D CAD and drawings for electrical hardware components (cast/injection molded housings, busbars, wire harnesses, insulators, switches etc).
• Selecting appropriate materials for electrical hardware, including plastics, metals, polymers and ceramics
• Creating design validation plans for electrical hardware
• High voltage power distribution systems
• DFM/DFA analysis
• Bolted joint design and analysis
• Rapid iteration cycles
• Supporting programs in all stages of the product life cycle, from early concepting to supporting production and field service

Nice To Haves

• Experience with solar arrays
• Experience designing wire harnesses (high voltage and low voltage)
• Experience with CATIA (3DX)
• Experience with performing thermal analyses (mixed convective/conductive/radiation HT)
• Experience with structural analysis (basic stress/strain and modal analysis)
• Experience with designing for automotive environments
• Experience performing DFMEAs on electric vehicle power systems/propulsion systems
• Experience with systems engineering and software based vehicle architectures

Responsibilities

• Work with the Product and Design teams to develop high level product requirements, and create lower level engineering requirements for your sub-systems by working with the various engineering teams (systems, controls/software, vehicle engineering)
• Review regulatory requirements and ensure all components are designed to meet them
• Work with the supply chain and finance teams to ensure all subsystems are meeting cost targets
• Perform Design Failure Modes & Effects Analysis (DFMEA) to highlight reliability and safety issues. Use the outputs of this process to create design fixes and drive test plans
• Create timelines and schedules for all subsystem development and work with the program team to ensure these are meeting high level milestones and development goals
• Create detailed CAD and drawings of all custom components. Work with the CAD/PLM team to ensure all packaging issues are resolved and all parts are released
• Select off the shelf components that meet all functional, durability, cost and quality needs
• Create tolerance stack analyses and apply appropriate GD&T controls to 3D geometries
• Hold design reviews with the cross functional team to ensure all considerations are taken into account
• Host core team meetings to push forward work and collaborate with the cross-functional teams
• Work with supply chain to select appropriate suppliers, and work with suppliers to ensure components can be manufactured by performing detailed design for manufacturing (DFM) analysis
• Create design validation plans (DVPs) by working with the test engineering team
• Perform all necessary analysis (thermal, structural, etc) to reduce risk of design failures and ensure we meet performance targets
• Build functional prototypes of subsystems to ensure early de-risking before full vehicle builds
• Perform engineering validation (EV) testing of subsystems to characterize performance and safety
• Work with the test engineering team to troubleshoot issues from highly accelerated life testing (HALT) and vehicle level test failures
• Create work instructions by working with the production operations teams and performing design for assembly (DFA) analysis
• Perform first article inspections of components from suppliers and work with in house quality engineering to triage quality issues
• Support prototype and production builds in Broomfield, CO factory (10-15% of time, depending on the phase of development)
• Support field service engineering of customer vehicles and marketing vehicles

Benefits

• Healthcare, Dental, Vision
• 401k
• Flexible Paid Time Off - that we actually want you to use!
• 8 Company Holidays + the company observes a period of scheduled downtime during the end of the year for a week, allowing all employees to enjoy a break
• 12 weeks paid parental leave
• $2,000 per year towards an RV trip of your own &/or professional development opportunities - we call this a LightTrip
• Lightship offers all of its full time employees and their dependents full benefits including health, dental and vision insurance and covers 100% of the insurance premium. We are on a mission to create a more healthful all-electric experience for a pastime that millions of families enjoy and believe strongly that our team should not have to worry about quality healthcare for themselves or their loved ones along the way.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior
• Education Level: No Education Listed