Senior Staff Mechanical Engineer - DC and AC Interconnection, BESS

Enphase Energy; Bengaluru; On-site; INR 4,200,000 - 7,000,000; Full time

Job summary

Enphase Energy in Bengaluru is seeking a Senior Staff Mechanical Engineer to own the mechanical design of HV DC/AC interconnection systems for MW/MWh-scale inverter and Battery Energy Storage Systems. This role requires hands‑on expertise and cross‑functional collaboration with electrical, thermal, sourcing, and manufacturing teams.

You will drive production‑ready designs, optimize BOM cost, perform FEM/FEA analyses, and mentor senior engineers while ensuring safety and reliability across

Qualifications

• BE/B.Tech in Mechanical Engineering or ME/M.Tech in a related discipline with 8+ years of experience.
• Proven experience in high‑voltage DC/AC interconnection mechanical design (800-1500V DC and 277/480V AC).
• Strong FEM/FEA, CAD (SolidWorks or equivalent), and manufacturing know‑how.

Responsibilities

• Own and drive HV DC/AC interconnection mechanical design for inverter and BESS projects.
• Design bulkhead connectors and busbar layouts meeting creepage, clearance, and insulation requirements.
• Perform FEM/FEA on interconnection assemblies and develop mechanical safety solutions for outdoor use.
• Lead cross‑functional teams, supplier reviews, and design reviews; mentor engineers.

Skills

HV interconnection design

FEM/FEA analysis

SolidWorks

UL/IEC standards

Cross-functional leadership

Design for manufacturing

3D prototyping / printing

Education

BE/B.Tech in Mechanical Engineering

ME/M.Tech in Product/Mechanical Design

Tools

EPDM

Job description

Enphase Energy is a global energy technology company and leading provider of solar, battery, and electric vehicle charging products. Founded in 2006, Enphase transformed the solar industry with our revolutionary microinverter technology, which turns sunlight into a safe, reliable, resilient, and scalable source of energy to power our lives. Today, the Enphase Energy System helps people make, use, save, and sell their own power. Enphase is also one of the fastest growing and innovative clean energy companies in the world, with approximately 80 million products installed across more than 160 countries.

We are building teams that are designing, developing, and manufacturing next‑generation energy technologies and our work environment is fast-paced, fun and full of exciting new projects.

Must be available to work on‑site at our Bangalore office 5 days per week.

About the role:

As a Senior Staff Mechanical Engineer, you will own and drive the mechanical design of DC and AC interconnection systems alongside other mechanical, electrical, and hardware engineers for MW/MWh‑scale utility inverter and Battery Energy Storage Systems (BESS) serving data centers, spanning outdoor cabinets and containerized platforms. This role requires deep, hands‑on expertise in the mechanical design of high‑voltage DC and AC interconnections — including busbars, cable harnesses, bulkhead connectors, and insulation and barrier systems — for 800V-1500V DC battery voltages and 277/480V AC voltages, with attention to creepage, clearance, insulation, and BESS safety compliance. You will work closely with electrical hardware, system, controls, thermal, sourcing, manufacturing, and quality teams to ensure the product meets safety, performance, reliability, manufacturability, serviceability, and cost targets — delivering production‑ready designs from concept through deployment while optimizing BOM cost.

What will you do:

• Own and drive the mechanical design of HV DC and AC interconnection systems — busbars, cable harnesses, bulkhead connectors, terminals, and insulation and barrier systems — interconnecting multiple inverter DC inputs to the battery and inverter AC outputs to the grid.
• Design custom bulkhead connectors for high‑voltage DC (800-1500V) and high‑voltage AC (277/480V) applications.
• Design busbar and conductor layouts that meet creepage, clearance, insulation coordination, and thermal‑expansion requirements.
• Integrate and package DC and AC fusing and high‑current DC and AC molded case circuit breakers (MCCBs) within the interconnection system.
• Develop electro‑mechanical solutions for outdoor applications that meet various Ingress Protection (IP) ratings.
• Perform product structural analysis across injection molded plastics, aluminum metal extrusions, copper busbars, and other materials.
• Conduct FEM/FEA (structural and thermal) on interconnection assemblies under various load, vibration, and thermal conditions.
• Support the mechanical aspects of interlocks, protection, sequencing, and poka‑yoke (error‑proof) connections for high‑voltage DC and AC interconnections.
• Work in cross‑functional teams of system integration, electrical hardware, and mechanical engineers.
• Support system architecture, cost‑reduction proposals, and failure root‑cause analysis.
• Prepare and execute test plans for structural and environmental validation (vibration, drop test, impact test, thermal test, thermal cycling, damp heat humidity test, connector reliability, and others).
• Conduct failure analysis and root‑cause identification.
• Support sourcing, manufacturing, and quality teams with mechanical expertise, and lead supplier selection and design reviews.
• Generate and review documentation, including concept proposals, analysis reports, component specifications, and review minutes.
• Provide technical leadership and mentor senior‑and‑staff‑level engineers.
• Serve as a DC and AC interconnection mechanical subject matter expert for current and next‑generation platforms.

Who You Are and What You Will Bring:

• BE/B.Tech in Mechanical Engineering with 12+ years of relevant industry experience, or a ME/M.Tech (Product Design, Mechanical Design, or a related discipline) with 8+ years of relevant industry experience.
• Strong fundamentals in engineering mechanics and strength of materials.
• Strong fundamentals in FEM/FEA (structural and thermal) analysis — a key requirement.
• Proven track record designing high‑voltage DC and AC interconnection mechanical systems (busbars, harnesses, connectors) in commercial/industrial products.
• In‑depth knowledge of creepage, clearance, insulation coordination, and high‑voltage mechanical safety for 800-1500V DC and 277/480V AC systems.
• In‑depth knowledge of design for manufacture for parts made through injection molding, sheet metal, stamping, extrusion, and machining.
• Proficiency with CAD tools (SolidWorks or equivalent) and EPDM.
• Working knowledge of standards such as UL 9540/9540A, UL1741, IEC 62109, and NEMA, as well as country‑specific standards.
• Thorough knowledge of product validation methods (vibration, drop test, impact test, thermal cycling, connector reliability, and others).
• Proficiency in tolerance analysis, worst‑case analysis (WCA), DPPM, DFMEA/AFMEA, and root‑cause analysis for field failures.
• Strong technical leadership skills, with the ability to lead programs, influence architecture decisions, and mentor senior‑and‑staff‑level engineers.
• Clear written and verbal communication, including strong presentation skills.
• Experience with high‑current busbar and high‑voltage connector mechanical design.
• Experience in design and sustaining activities on high‑volume products (500k+ to 1 million per annum).
• Rapid prototyping with 3D printing or high‑temperature resin materials.
• Field quality improvement and cost reduction through Value Analysis/Value Engineering (VAVE).