Senior Mechanical Engineer

Hewlett Packard Enterprise•Sunnyvale, CA

4d•Onsite

About The Position

The Senior Mechanical Engineer is a hands-on individual contributor responsible for mechanical design, structural analysis, development, and qualification of complex networking systems from concept through production. Reporting to the Head of Mechanical Engineering, the role works independently to solve engineering problems and collaborates with cross-functional teams in a fast-paced product development environment. The engineer provides mechanical design and structural analysis support across product development programs, including chassis design, system packaging, reliability, and manufacturability. The role emphasizes structural analysis and FEA, including shock and vibration analysis and simulation-to-test correlation. The engineer participates in mechanical design, prototype evaluation, laboratory testing, root-cause investigations, and design improvements to ensure product reliability and structural integrity. The position is onsite, with the expectation of primarily working from an HPE office.

Requirements

At least 7 years of experience in electromechanical product development.
Bachelor of Science 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.
Expert-level proficiency with 3D solid modeling tools.
Experience meshing sheet-metal geometries as solid or shell elements, and knowledge of 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.
Strong working knowledge of Young’s modulus and coefficients of thermal expansion of common materials used in ASIC and cooling components.
Hands-on experience in dynamic testing.
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.
Strong communication and leadership skills, with 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.
Experience with LS-Dyna and response spectrum analysis.
Previous training in strain-gauge applications on PCBs and data analysis involving principal microstrain and strain rate.
Experience with accelerometer G-value data filtering and analysis from dynamic tests such as vibration and shock.
Knowledge of dye-and-pry, Shadowmoire, and operation of 3D-scanning metrology equipment.
Experience modeling die warpage due to thermal effects and heatsink loading.

Responsibilities

Develop and own structural FEA simulation capabilities supporting multiple new product introduction projects and sustaining issues.
Continuously improve simulation accuracy through test correlation and model refinement.
Maintain and coordinate multiple FEA projects involving internal functions and external partners.
Provide design guidance from the concept phase by running FEA studies on areas of concern.
Support 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.
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 project design reviews, and take responsibility for system structural integrity.
Communicate recommended design changes to hardware leads, supported by FEA model results.
Collaborate with ASIC development teams to generate 3D ASIC models from package outline drawings, including BGAs, and conduct near-package or co-package connector placement and floorplan studies as required.
Support manufacturing and operations in improving production yield through FEA studies or limited design of experiments in the lab.
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.