Lead Mechanical Engineer

Ford; Bengaluru; On-site; INR 1,500,000 - 2,100,000; Full time

Job summary

Ford Bengaluru seeks a Lead Mechanical Engineer to drive design of mechanical assemblies for high‑voltage EV power electronics. You will mentor juniors and collaborate across disciplines to deliver robust, manufacturable solutions for onboard chargers, DC/DC converters, BMS, and motor controllers.

You will lead prototyping, testing, supplier collaboration, and design-for-excellence activities to ensure performance, cost, and reliability targets are met.

Qualifications

• Bachelor’s degree in mechanical engineering or related field.
• 8+ years of electromechanical product design for high‑volume manufacturing.
• Strong knowledge of GD&T and tolerance stack‑up analysis.
• DFM across casting, machining, and plastics; plastic design expertise.
• Experience with PLM tools (Teamcenter or similar).
• CAD proficiency in CATIA V6/3DEXPERIENCE; prototyping and testing experience.

Responsibilities

• Design and develop mechanical components for EV power electronics with focus on performance, cost, and reliability.
• Collaborate with electrical, manufacturing, testing, and quality teams to ensure manufacturability.
• Develop and validate prototypes using rapid prototyping techniques.
• Work with global suppliers to ensure material and process feasibility from concept to production.
• Support product validation through test planning, execution, and documentation.
• Review simulations (FEA) and implement design improvements.
• Mentor junior engineers and participate in technical reviews.

Skills

GD&T

Tolerance stack-up

DFM

Plastic design

Teamcenter

CATIA V6/3DEXPERIENCE

Prototyping

Electromechanical design

High-volume manufacturing

Education

Bachelor's degree in Mechanical Engineering

Master's degree in tool design (nice-to-have)

Tools

CATIA V6/3DEXPERIENCE

Teamcenter

Job description

As a Lead Mechanical Engineer, you will be part of Ford's Global Advanced Product Development team, working on critical systems such as onboard chargers, DC/DC converters, battery management systems, and motor controllers. You will collaborate with cross‑functional teams to design, prototype, validate, and deliver mechanical solutions for high‑voltage power electronics in electric vehicles.

This role offers the opportunity to work on cutting‑edge technologies and influence designs that reach global production.

• Design and develop mechanical components and assemblies for EV power electronics systems, ensuring performance, cost, and reliability targets are met.
• Collaborate with electrical, manufacturing, testing, and quality teams to ensure design‑for‑excellence (manufacturability, reliability, serviceability).
• Develop and validate prototypes using rapid prototyping techniques.
• Work closely with suppliers from concept to production to ensure material and process feasibility.
• Support product validation through test planning, execution, and documentation.
• Identify and resolve manufacturing and quality issues using structured problem‑solving methods (e.g., FMEA, root cause analysis).
• Support development of assembly processes and test fixtures.
• Review engineering simulations (FEA) and incorporate improvements into designs.
• Mentor junior engineers and contribute to technical reviews.

Must‑Have

• Bachelor's degree in Mechanical Engineering or related field.
• 8+ years of experience in electromechanical product design for high‑volume manufacturing.
• Strong understanding of:
• GD&T (Geometric Dimensioning & Tolerancing)
• Tolerance stack‑up analysis.
• Design for manufacturing (DFM) across casting, machining, and plastics.
• Plastic product design expertise.
• Experience with PLM tools (e.g., Teamcenter or similar).
• Proficiency with CAD tools such as CATIA V6 / 3DEXPERIENCE.
• Experience in prototyping, testing, and production release.

Nice‑to‑Have

• Master's degree or certification in tool design (e.g., GTTC, NTTF).
• Experience in high‑voltage electronics packaging.
• Experience in EV systems (OBC, DC/DC converters, EV charging systems).
• Experience working with global suppliers.