Senior Mechanical Engineer

Advanced Energy Industries, Inc • Fort Collins, CO

52d • $95,000 - $145,000 • Hybrid

About The Position

As a Mechanical Engineer III in the Plasma Power Group, you will lead the design, analysis, and validation of mechanical systems for high-power products used in plasma processing applications. You will work with a high degree of independence and technical judgment to develop innovative, manufacturable, and reliable solutions for complex power electronics. This role requires strong expertise in thermal management, materials selection, and mechanical design in demanding environments, along with the ability to drive cross-functional collaboration, mentor other engineers, and influence product architecture from concept through production.

Requirements

• Advanced proficiency in SolidWorks or equivalent 3D CAD software for complex part and assembly design.
• Strong experience with sheet metal, machined, molded, extruded, stamped, and 3D-printed parts and associated manufacturing processes.
• Demonstrated expertise in tolerance analysis and GD&T (ANSI Y14.5).
• Hands-on experience with lab testing, instrumentation, and data collection for design validation and troubleshooting.
• Experience creating and managing Bills of Materials (BOMs), engineering changes, and released product documentation.
• Experience designing and routing power and communication cables for complex systems.
• Proven ability to collaborate effectively with suppliers, manufacturing, and supply chain teams to drive manufacturable, cost-effective solutions.
• Strong analytical and problem-solving skills, with the ability to independently drive technical investigations and design decisions.
• Bachelor’s Degree in Mechanical Engineering or Materials Science
• 5-8 years of mechanical engineering experience with a BS degree, or 3+ years of experience with an MS degree.
• Demonstrated experience leading substantial mechanical design efforts for complex products or subsystems from concept through release.
• Experience designing thermal management systems such as cold plates, heat sinks, and air/liquid cooling solutions.

Nice To Haves

• Background in electronics packaging or RF systems preferred.
• Familiarity with materials suitable for use in high RF field environments preferred.
• Demonstrated application of DFM/DFA principles and participation in design reviews, root-cause analysis, and continuous improvement initiatives preferred.
• Experience with Ansys or similar simulation tools for thermal and structural analysis preferred.
• Experience with scripting (e.g., Python or MATLAB) for test automation or data analysis preferred.

Responsibilities

• Lead mechanical engineering activities across all phases of the product development lifecycle, from concept generation through production release and sustaining support.
• Own the design and analysis of thermal management systems including cold plates, heat sinks, and air/liquid cooling mechanisms for high-power electronics.
• Develop robust mechanical designs and detailed documentation for sheet metal, machined, molded, extruded, stamped, and 3D-printed components and assemblies.
• Design and route power and communication cabling to meet system performance, safety, regulatory, and serviceability requirements.
• Create, maintain, and drive accuracy of Bills of Materials (BOMs), engineering change documentation, and released product data throughout the lifecycle.
• Partner with suppliers, manufacturing, and supply chain teams to optimize designs for manufacturability, cost, quality, and delivery.
• Perform and interpret thermal and structural simulations using tools such as Ansys, and correlate results with laboratory and prototype test data.
• Perform tolerance stack-up analysis and apply GD&T per ANSI Y14.5 to ensure fit, function, manufacturability, and interchangeability.
• Plan and execute experiments, develop test methods, and automate data collection and analysis for performance validation and root-cause investigation.
• Apply DFM/DFA principles to improve manufacturability, testability, serviceability, and product reliability.
• Lead prototype builds, hands-on testing, design reviews, and troubleshooting efforts for complex mechanical and electro-mechanical issues.
• Evaluate and select materials and mechanical solutions suitable for environments with high RF fields, thermal loads, and demanding operating conditions.
• Provide technical guidance to other engineers and technicians, and contribute to mechanical design standards, best practices, and continuous improvement initiatives.
• Collaborate across engineering disciplines to ensure robust, manufacturable, high-quality product designs that meet customer and business objectives.

Benefits

• Medical - multiple medical plans are available to choose from
• Short and long-term disability and life insurance
• Health savings and flexible spending accounts
• Generous time off policy starting with 3 weeks of paid vacation, 7 days of paid sick time, and 12 paid holidays
• 8 hours of paid volunteer time off
• 8 weeks of paid parental leave for both Moms and Dads
• Company matched 401(k)
• Tuition reimbursement
• Expanded mental health coverage and employee assistance programs
• Other voluntary benefits include critical illness, accident and hospital indemnity, pet insurance, identify theft, and legal assistance
• Annual pay-for-performance incentive plan
• Discounted Employee Stock Purchase Plan

What This Job Offers

• Job Type: Full-time
• Career Level: Senior