Electronics Packaging Design Engineer

TVS Motor; Krishnagiri District; On-site; INR 1,500,000 - 2,200,000; Full time

Job summary

TVS Motor is seeking an Electronics Packaging Design Engineer to lead the mechanical design of enclosures for EV/HEV electronics including motor controllers, VCUs and chargers. You will ensure protective, manufacturable packaging, thermal management, IP sealing and serviceability within an advanced automotive environment.

The role requires 6–10 years in mechanical design for electronic/mechatronic products, with demonstrated concept-to-series experience and collaboration with CAD/CAE teams.

Qualifications

• 6–10 years in mechanical design for electronic/mechatronic products.
• Experience with electronics enclosures, controllers, EV chargers, docking or battery swapping stations.
• At least two products from concept to series production.

Responsibilities

• Develop mechanical concepts and detailed designs for enclosures and housings of EV controllers, chargers and charging stations.
• Package PCBs, power modules, busbars, connectors, sensors, cables and cooling elements within the envelope.
• Design mounting, grounding, strain-relief and interface features to vehicle or station structure.
• Own mechanical design change loop with electronics, thermal and system teams; drive design reviews.

Skills

Tolerance analysis

3D CAD modelling

DFMEA

DFM/DFA

Thermal management

Education

B.E./B.Tech in Mechanical/Mechatronics

M.E./M.Tech in Mechanical/Mechatronics

Tools

PTC Creo

CATIA

Windchill

Job description

Job Summary

The Mechatronics Electronics packaging engineer will design and release the mechanical enclosures and packaging of automotive mechatronic products in the EV/HEV portfolio - motor controllers, VCUs, chargers, DC-DC units, charging stations, etc. so that the electronics and electrical components inside them are correctly protected, cooled, sealed, mounted and serviceable. The role will ensure that designs are manufacturable, cost-effective and validated to automotive environmental and durability requirements. The role owns the mechanical design from concept and CAD through tolerance analysis, prototype build and validation to tooling release and series change management.

Role Details

Job Title / Role: Electronics Packaging Design Engineer

Department: RD-EV Sys DD

Location: Hosur

Education Qualification: B.E. / B.Tech / M.E. / M.Tech in Mechanical, Mechatronics, Automotive or Production Engineering

Required Experience: 6 - 10 years in mechanical design for electronic and mechatronic products. Electronics enclosures, controllers, EV chargers, docking or battery swapping stations. At least two or more products taken from concept to series production.

Role Description

Accountability: Mechanical Design and Packaging of Electronic Assemblies

• Develop mechanical concepts and detailed designs for enclosures and housings of EV controllers, chargers, charging stations. Balancing electrical, thermal, EMC, cost and serviceability needs.
• Package PCBs, power modules, busbars, connectors, sensors, cables and cooling elements within the available envelope, including creepage/clearance and HV isolation distances.
• Design mounting, fixing, grounding, strain-relief and interface features to the vehicle or the station structure.
• Own the mechanical design change loop with the electronics, thermal and system teams and drive concept selection through design reviews.

Accountability: CAD Modelling, Drawings, GDT and Tolerance Analysis

• Create and maintain parametric 3D models and assemblies in PTC Creo / CATIA following the applicable modelling standards.
• Release 3D and 2D manufacturing drawings with complete and correct GDT and inspection-ready dimensioning.
• Perform worst-case and statistical tolerance stack-up analysis for critical fits, sealing surfaces, connector alignment and thermal interfaces.
• Maintain models, drawings, BOMs and revisions in the PLM system (Windchill).

Accountability: Design for Manufacture, Assembly and Material / Process Selection

• Select materials and manufacturing processes appropriate to volume, cost and performance.
• Apply DFM and DFA principles: draft angles, wall thickness, ribs, parting lines, fastener count and separation and assembly sequence.
• Be the champion for part scalability, modularity and cost reduction.
• Work with tool makers and suppliers on tool feasibility, moldflow feedback, tolerance capability and troubleshooting.
• Own the DFMEA for the mechanical design and drive the resulting design actions to closure.

Accountability: Thermal, Sealing, Structural and NVH Design Integration

• Design the thermal interface for power electronics components: heat sinks, cooling path, thermal interface materials, potting and fan integration.
• Design sealing and ingress protection concepts (gaskets, O-rings, adhesives, breathers, vents) to meet IP targets and validate them by test.
• Define and verify structural and vibration performance of housings, brackets and mounts: interpret FEA and CFD studies with the CAE team.
• Address NVH, thermal expansion, corrosion protection, surface treatment and material compatibility in the design.

Accountability: Prototype Build, Testing and Design Validation

• Plan and support prototype and pre-series builds, including rapid prototyping, fixtures, assembly instructions and build issue resolution.
• Define the mechanical DVP: vibration, mechanical shock, drop, thermal cycling and shock, salt spray, dust and water ingress and durability testing.
• Analyse test results and field/warranty issues. Perform root-cause analysis and implement design countermeasures.

Accountability: Supplier, Tooling and Documentation Support

• Support supplier selection and technical evaluation for castings, mouldings, sheet metal parts and assemblies.
• Release and manage engineering change notes, deviations and BOM updates through to series implementation.
• Maintain design guidelines, standard parts libraries and lessons learned for electronic packaging.
• Support cost, weight and packaging target tracking together with purchasing and program management.

Disclaimer: This job posting has been aggregated from external source. Role details, content, and availability are subject to change. Applicants are advised to confirm the latest information directly on the company website before applying.