Principal Mechanical Engineer

Advanced Energy; Colorado; On-site; USD 120,000 - 180,000; Full time

Job summary

Advanced Energy in Fort Collins, CO, is seeking a Principal Mechanical Engineer in the Plasma Power Group to lead the design, analysis, and validation of mechanical systems for RF generator systems used in plasma processing.

You will drive thermal management, material selection, and manufacturability, mentor junior engineers, and collaborate with electrical, RF, and reliability teams to deliver high-power solutions. This role shapes next-generation plasma power solutions.

Qualifications

• Expert proficiency in SolidWorks or equivalent 3D CAD software.
• Advanced knowledge of tolerance analysis and GD&T (ANSI Y14.5).
• Strong hands-on experience with lab testing, instrumentation, and data analysis.
• Ability to self-manage projects from concept to release, including schedule and cost control.
• Proficiency with Ansys, COMSOL, or similar simulation tools.
• Background in electronics packaging, RF systems, or high-power applications.

Responsibilities

• Lead mechanical engineering efforts across all product development phases.
• Architect and optimize thermal management systems including cold plates, heat exchangers, and active cooling solutions.
• Perform advanced simulations (thermal, structural, fluid flow) using tools like Ansys or COMSOL; validate results through empirical testing.
• Design mechanical components using SolidWorks or equivalent CAD tools, applying GD&T and tolerance stack-up analysis per ANSI Y14.5.
• Develop mechanical designs for sheet metal, machined, molded, extruded, stamped, and 3D-printed parts.
• Collaborate with suppliers and internal teams to ensure manufacturability, cost-effectiveness, and supply chain resilience.
• Mentor junior engineers and contribute to technical reviews, design standards, and best practices.
• Interface with customers and OEMs to define and negotiate mechanical design requirements.

Skills

SolidWorks

Tolerance analysis & GD&T

Lab testing & data analysis

Project management

RF/high-power electronics background

Tools

Ansys

COMSOL

Job description

Principal Mechanical Engineer

ABOUT ADVANCED ENERGY

Advanced Energy (Nasdaq: AEIS) is a global leader in the design and manufacturing of highly engineered, precision power conversion, measurement and control solutions for mission-critical applications and processes. AE's power solutions enable customer innovation in complex applications for a wide range of industries including semiconductor equipment, industrial, manufacturing, telecommunications, data center computing and healthcare. Advanced Energy has devoted four decades to perfecting power for its global customers and is headquartered in Denver, Colorado.

WHY BE A PART OF ADVANCED ENERGY?

Some people say it's like working in the best of two worlds. We operate like an agile, growing, small company - you can see your work make a difference to the company every day. Things move quickly and you can see and feel it. At the same time, we're a global company founded in 1981 and have been publicly traded for more than 28 years. We have a strong cash position, deep trust and partnership with leading customers, a global best-in-class operations capability, and a proven leadership team. We have a track record and resources to make things happen both organically and inorganically. Being part of a nimble company with a solid foundation attracts team members that are capable, driven and like a challenge. Our employees collaborate and know how to have fun inventing, working, building and winning together. At our core, we are Advanced Energy - powering the future, together.

POSITION SUMMARY:

As a Principal Mechanical Engineer in the Plasma Power Group, you will lead the design, analysis, and validation of mechanical systems for RF generator systems used in plasma processing applications. You will drive innovation in thermal management, materials selection, and mechanical design for high-power electronics in complex environments. This role requires cross-functional collaboration, technical leadership, and mentoring of junior engineers. You will influence product architecture, ensure manufacturability, and contribute to the success of next-generation plasma power solutions.

RESPONSIBILITIES:

• Lead mechanical engineering efforts across all phases of the product development lifecycle
• Architect and optimize thermal management systems including cold plates, heat exchangers, and active cooling solutions
• Perform advanced simulations (thermal, structural, fluid flow) using tools like Ansys or COMSOL; validate results through empirical testing
• Design mechanical components using SolidWorks or equivalent CAD tools, applying GD&T and tolerance stack-up analysis per ANSI Y14.5
• Develop mechanical designs for sheet metal, machined, molded, extruded, stamped, and 3D-printed parts
• Design and route power and communication cables to meet system, regulatory, and EMI requirements
• Create and manage complex Bills of Materials (BOMs) and configuration control across multiple product lines
• Collaborate with suppliers and internal teams to ensure manufacturability, cost-effectiveness, and supply chain resilience
• Specify and execute experiments to validate design concepts and performance
• Apply DFM/DFA principles to improve manufacturability, serviceability, and reliability
• Evaluate and select materials for high RF field environments and harsh operating conditions
• Mentor junior engineers and contribute to technical reviews, design standards, and best practices
• Communicate effectively and work collaboratively with cross-functional teams including electrical engineering, RF engineering, supply chain, compliance, reliability, product management, factory/operations, and leadership
• Interface with customers and OEMs to define and negotiate mechanical design requirements

WORK ENVIRONMENT:

• Location: Onsite in Fort Collins, CO
• Work is split between a standard office environment, engineering lab, and/or clean room. Occasional domestic and international travel may be required for supplier visits, testing, or customer support

QUALIFICATIONS:

• Expert proficiency in SolidWorks or equivalent 3D CAD software
• Advanced knowledge of tolerance analysis and GD&T (ANSI Y14.5)
• Strong hands-on experience with lab testing, instrumentation, and data analysis
• Ability to self-manage projects from concept to release, including schedule and cost control
• Proficiency with Ansys, COMSOL, or similar simulation tools preferred
• Background in electronics packaging, RF systems, or high-voltage/high-power applications preferred

EXPERIENCE:

• 10+ years of mechanical engineering experience
• Proven experience designing and validating thermal management systems
• Experience managing BOMs and configuration control in a multi-product environment
• Experience with materials selection for high RF field and high-temperature environments preferred
• Strong background in DFM/DFA and reliability engineering preferred
• Experience work