Senior Mechanical Engineer

LayerZero Power Systems, Inc.; Aurora (OH); On-site; USD 85,000 - 115,000; Full time

Benefits offered by this job

Competitive pay with performance incentives

100% company-paid medical, dental, and vision

401(k) with company match

3 weeks PTO, 10 paid holidays, and 2 floating holidays

Job summary

LayerZero Power Systems, Inc. in Aurora, Ohio, is seeking a Senior Mechanical Engineer to lead the design of critical power systems products. You will utilize your expertise in mechanical design and analysis to address complex technical challenges, ensuring reliability and performance of our Static Transfer Switches and Power Distribution Units. This role requires advanced FEA and CFD simulation skills, along with a strong background in thermal management and 3-D CAD tools. Join a thriving company committed to innovation and professional growth.

Qualifications

• 5+ years of experience in mechanical design and simulation for electromechanical systems.
• Expert in FEA and CFD.
• Proven experience with design for manufacturability in sheet metal and electro‑mechanical assemblies.

Responsibilities

• Lead mechanical design for Static Transfer Switches and Power Distribution Units.
• Perform advanced FEA and CFD simulations.
• Define parameters for 3rd-party testing to achieve industry certifications.

Skills

Mechanical design and simulation

FEA

CFD

3-D CAD tools

Thermal management

Education

Bachelor’s or Master’s degree in mechanical engineering or related field

Tools

Solid Edge

Job description

Description

LayerZero Power Systems, LLC. is a leader in power management products for mission and process critical applications. Our customer base is comprised of companies in the computer service provider (on-line commerce, streaming, hosting, etc.), semiconductor manufacturing and financial sectors.

LayerZero provides innovative products to ensure user safety and ultimate reliability of computers, servers, communication gear, and other critical equipment. LayerZero manufactures best-in-class products representing high-end solutions. LayerZero Power Systems is on a trajectory of sustained growth, with a loyal base of existing Fortune 100 customers and an expanding portfolio of new customers. To meet the challenge of growth and opportunities, LayerZero Power Systems is seeking additional Mechanical Engineers to join the engineering team.

Position Summary

We are seeking a Senior Mechanical Engineer with a mastery of first principles engineering to lead the structural, thermal, and manufacturing integration of next-generation power systems products. The ideal candidate will play a key role in solving complex technical challenges, ensuring every design is validated, optimized, and built to deliver uncompromising, long-term reliability for our Static Transfer Switches and Power Distribution Units.

Key Responsibilities

• Lead mechanical design and analysis activities for power systems products including Static Transfer Switches and Power Distribution Units.
• Drive mechanical and thermal design by performing advanced FEA and CFD simulations.
• Validate analytical models through calculation, prototype testing and measurement.
• Optimize 3D CAD models specifically for our vertically integrated manufacturing capabilities.
• Support sustaining engineering efforts to improve existing product designs.
• Embed industry standards into the physical geometry, ensuring operator safety and clearance constraints are fundamental design inputs rather than post-design checks.
• Define the parameters and provide technical support for 3rd-party testing to achieve and maintain industry certifications.
• Define and support internal product testing parameters for both prototypes and final production units.
• Contribute to rigorous design reviews, establish internal engineering standards, and coach junior engineers in advanced analysis techniques.
• Lead Root Cause Analysis (RCA) and provide high-level technical resolution for complex field support issues.

Requirements

• Bachelor’s or Master’s degree in mechanical engineering or related field (PhD preferred).
• 5+ years of experience in mechanical design and simulation for electromechanical systems.
• Experience with 3-D CAD tools (Solid Edge preferred) – Required.
• Expert in FEA and CFD.
• Proven experience with design for manufacturability and design for reliability in sheet metal and electro‑mechanical assemblies.
• Strong understanding of thermal management, heat transfer, structural mechanics, and vibration analysis.
• Hands‑on experience with thermal and vibration testing.
• Familiarity with electrical power systems is a strong plus.
• Knowledge of NFPA 70, UL, IEC, CSA, NOM or ANSI standards for power equipment.
• Excellent communication and documentation skills.
• An active Professional Engineer (PE) License is highly desired.

What We Offer

• Competitive pay with performance incentives
• 100% company‑paid medical, dental, and vision
• 401(k) with company match
• 3 weeks PTO, 10 paid holidays, and 2 floating holidays

Why You Will Love Working with Us

• Impact: Develop your skills and expertise in a rapidly growing industry, with your work directly influencing the success of mission‑critical projects.
• Innovation: Immerse yourself in an environment that celebrates forward‑thinking and continuous improvement.
• Collaborative spirit: Work closely with engineers, marketers, and other professionals to bring ideas to life.
• Grow with us: We are committed to your personal and professional development, offering endless opportunities to improve your skills and advance your career

At LayerZero, we are proud to be an Equal Opportunity Employer. We welcome and celebrate diversity, and we are committed to creating an inclusive environment for all employees.