Senior Mechanical Engineer, Design and Thermal Analyses
About The Position
Trystar develops power equipment through cross-functional engineering and manufacturing collaboration. This hands-on senior individual-contributor role combines mechanical requirements, design, packaging, CAD, and drawings with independent thermal and fluid modelling, prototype validation, test correlation, and manufacturing handoff. Assignments support platform development across products such as power converters, switchboards, and load banks, with a focus on manufacturable equipment and rigorous thermal evaluation for higher power density in limited footprints. The engineer reports to the Senior Engineering Manager for RDE Power Distribution, who prioritizes assignments and resolves conflicting project demands. The role includes technical mentoring and support for established release decisions, but does not include independent product release authority, automatic leadership of all products across sites, or formal people-management responsibilities. The position is hybrid at any listed Trystar site, with travel of up to 20% within the United States and Canada. On-site frequency is yet to be established; the hybrid arrangement is not remote-only.
Requirements
- Bachelor’s degree in mechanical engineering or an accepted equivalent from an accredited program.
- At least 7 years of relevant experience.
- Hands-on experience in mechanical design, packaging, CAD models, and drawings.
- Ability to independently perform and interpret thermal and fluid modelling.
- Experience with physical test correlation and prototype validation.
- Experience preparing and maintaining controlled technical documentation.
- Effective cross-functional communication.
- Ability to clearly define assumptions, boundary conditions, operating cases, acceptance limits, and uncertainty, and to address unresolved discrepancies.
- Ability to communicate technical reasoning clearly, make evidence-based design decisions, connect simulation results to practical design changes, and communicate uncertainty without obscuring risk.
- Technical skills in mechanical design and drafting, product packaging, computational fluid dynamics and other thermal and fluid modelling, prototype testing, and correlation of simulation results with physical measurements.
- CAD software skills, such as SolidWorks or equivalent.
Nice To Haves
- Experience with power electronics, high-power equipment, or load banks.
- Structural finite element analysis experience.
- Experience with advanced cooling methods where applicable.
- Knowledge of manufacturing processes and applicable equipment standards.
- Experience with controlled product-release systems.
- Equivalent CAD and analysis software is acceptable; no specific software brand, certification, or license is mandatory.
Responsibilities
- Own mechanical design for assigned products from requirements through preparation of finished-product release packages.
- Translate requirements into product packaging, part and assembly models, CAD layouts, production drawings, and other controlled mechanical artifacts.
- Develop enclosures and assemblies using materials and processes such as sheet metal, plastics, and extrusions, designing for safety, reliability, manufacturability, serviceability, and platform reuse.
- Coordinate PCB mounting, structural interfaces, access, serviceability, and electrical packaging with electrical and power conversion engineers while maintaining distinct design ownership.
- Develop and interpret thermal and fluid models, including computational fluid dynamics when appropriate; define and communicate assumptions, boundary conditions, operating cases, acceptance limits, uncertainty, and limitations.
- Evaluate applicable air, liquid, immersive, and thermosiphon cooling concepts; analyze component temperatures, heat dissipation, flow, and power density, and translate results into design decisions.
- Design and integrate thermal-management components, including cold plates, heat exchangers, busbars, pumps, fans, and thermal control loops.
- Lead cross-functional mechanical design reviews for assigned work, assessing DFM, assembly, maintenance access, robustness, FMEA, AFMEA, IP ratings, seismic and harsh-environment requirements, and applicable standards.
- Support NRTL construction reviews and established design and release processes by preparing design packages and objective evidence of compliance with applicable requirements.
- Plan and support prototype builds and validation with the testing team; design test fixtures and perform required thermal, flow, HALT, vibration, and shock testing.
- Correlate measured temperatures, flow, and other responses with analytical predictions; investigate discrepancies, document causes and resolutions, and refine designs before manufacturing handoff.
- Prepare complete manufacturing work packages, including bills of materials, drawings, build guidance, and controlled technical documentation in applicable product data management and release systems.
- Partner with Quality, Manufacturing, Sourcing, and suppliers to resolve assembly and field issues; evaluate materials and production methods; manage supplier changes, obsolescence, and substitutions; and introduce automation or rapid prototyping where beneficial.
- Develop reusable platform designs and validated analysis methods to increase development speed and improve product performance across Trystar’s portfolio.
- Represent Trystar at technical conferences and build productive relationships with academic institutions and external technical partners.
- Provide technical mentoring to colleagues as appropriate.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
