Mechanical Engineer IV

Stored Energy Systems LLC (SENS); Longmont (CO); Hybrid; USD 130,000 - 140,000; Full time

Benefits offered by this job

Free gym with 24/7 access

Free EV charging

Breakfast and Lunch Café

After hours Grab & Go snacks

Basketball court

Walking paths

Job summary

Stored Energy Systems LLC (SENS) is seeking an experienced Mechanical Engineer to advance cooling and packaging for power products from concept through production. You will design enclosures for PCB and system levels, optimize thermal paths, and ensure manufacturability across sheet metal, plastic, and die castings.

The role involves thermal modeling in SolidWorks, collaboration with other engineers, and participation in design reviews.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field.
• 8+ years of relevant experience.
• Advanced knowledge of 3D CAD modeling software (SolidWorks preferred) with experience in electronics assembly design and packaging of physical components.
• Experience with common manufacturing methods including: sheet metal, plastic, and die castings components and/or assemblies.
• Experience with SolidWorks Flow Simulation (or similar tool) for thermal modeling and design validation.
• Ability to independently design functional, manufacturable, aesthetic and cost-controlled components.
• Basic knowledge of electrical components including circuit breakers, wiring, and terminal blocks.
• Experience taking a design from concept into volume production.
• Flexible team player who actively establishes and maintains effective working relationships and who is willing to multi-task and help wherever needed.

Responsibilities

• Develop innovative enclosures at both the PCB and system level using sheet metal, plastic, and die castings to meet size, cost, and thermal requirements.
• Model assemblies and components in SolidWorks to ensure fitment and proper cooling.
• Perform thermal modeling to maximize cooling and limit temperatures in harsh environments.
• Analyze and test designs to meet engine and seismic vibration requirements.
• Specify wire harnesses and thermal components in electrical assemblies.
• Specify materials, finishes, hardware, components, fixtures, labels, and graphics.
• Support validation, testing, and production release of mechanical components/assemblies.
• Conduct peer-to-peer and cross-functional design reviews.
• Create technical documentation including specs, drawings, BOMs, and assembly docs.
• Provide problem resolution support for production and field issues.
• Design improvements and updates to existing products.

Skills

8+ years experience

SolidWorks

Thermal modeling

Electronics packaging

Sheet metal & plastics

3D CAD

Cross-functional teamwork

Education

Bachelor’s degree in Mechanical Engineering

Tools

SolidWorks Flow Simulation

Job description

Stored Energy Systems (SENS) is an award-winning manufacturer of premium quality power conversion products located in Longmont, CO. In business for over 50 years, SENS is the market leader with a proven track record of providing highly reliable battery chargers, DC power systems, and related products to industrial markets. For more information on our company please see our web site at www.sens-usa.com .

View the SENS Product Catalog

Summary

SENS is looking for an experienced Mechanical Engineer with experience in cooling and packaging electronic components to join our engineering team and to build on our successful line of power products. This individual will help design and develop industrial battery chargers and inverters, engine starting systems, and DC back-up power systems across a wide power range (150W to 100kW). This person will be involved from concept investigation and design, through successful production launch and support of these products.

Responsibilities

• Develop innovative enclosures at both the PCB and system (cabinet) level, using sheet metal, plastic, and die-castings that meet challenging size, cost, and thermal/cooling requirements.
• Work with other engineers to define and model assemblies and associated components, including printed circuits boards, in SolidWorks to ensure fitment and proper cooling.
• Complete thermal modeling and designs in SolidWorks to maximize cooling and limit component temperatures for operation in industrial and outdoor environments.
• Analyze and test designs to meet engine and seismic vibration requirements.
• Specify wire assemblies, harnesses, and thermal components in electrical assemblies.
• Specify materials, finishes, hardware, components, fixtures, labels, and graphics.
• Participate in the validation, testing, and production release of mechanical components/assemblies.
• Conduct peer to peer and cross-functional design reviews.
• Create technical documentation throughout the development process including specifications, mechanical drawings, Bill of Materials, and assembly documents.
• Provide problem resolution support for production and field issues as needed.
• Design improvements and updates to existing products.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering or related Engineering field.
• 8+ years of relevant experience.
• Advanced knowledge of 3D CAD modeling software (SolidWorks preferred) with experience in electronics assembly design and packaging of physical components.
• E xperience with common manufacturing methods including: sheet metal, plastic, and die castings components and/or assemblies.
• Experience with SolidWorks Flow Simulation (or similar tool) for thermal modeling and design validation.
• Ability to independently design functional, manufacturable, aesthetic and cost-controlled components.
• Basic knowledge of electrical components including circuit breakers, wiring, and terminal blocks.
• Experience taking a design from concept into volume production.
• Flexible team player who actively establishes and maintains effective working relationships and who is willing to multi-task and help wherever needed.

Preferred Qualifications

• Knowledge of forced air and passive cooling strategies for high power electronics.
• Experience with battery energy storage systems and power conversion equipment.
• Familiarity with UL safety standards, NEMA/IP, seismic, and vibration testing.

Location

This position is located in Longmont, CO with flexibility to work a hybrid schedule once fully trained.

Base Compensation

$130,000 - $140,000 is the projected annual base salary range for this role and will be determined on the candidate’s overall qualifications and experience.

Bonus

This position is eligible for an annual bonus based on individual and company performance.

Closing Date

S ept ember 5th. While we expect to keep the position open through this date, the posting may be extended or closed early based on applicant volume and hiring needs.

Onsite Perks

• Free gym with 24/7 access
• Free Electric Vehicle charging
• Breakfast and Lunch Café
• After hours Grab & Go snacks
• Basketball court
• Walking paths

Benefits

• Paid Time Off
• Paid holidays
• Medical insurance
• Dental insurance
• Vision insurance
• Short-term and long-term disability
• Life insurance
• 401(k) plan with immediate vesting
• Employee referral program

Culture

At SENS, our culture is rooted in a set of core values that reflect who we are and how we work. In a recent 2025 poll, our employees identified the values that best define us: “Innovative”, “Respectful”, “Inviting”, “Flexible”, “Collaborative”, and “Growth Driven”. Our team describes us as a dynamic, forward-thinking company where everyone has the opportunity to thrive.

Equal Opportunity Statement

We pride ourselves on being an equal opportunity employer, fully dedicated to fostering inclusion and diversity. We welcome all applicants, regardless of race, color, religion, sex, sexual orientation, gender identity, genetic information, national origin, age, disability, veteran status, or any other legally protected characteristic.