Senior Mechanical Engineer - High Power System

Facade Today; United States; On-site; USD 110,000 - 160,000; Full time

Job summary

Voltify is seeking an experienced Mechanical Engineer to lead mechanical and thermal design for high‑voltage DC‑DC converters, inverters, and busbars. You will craft heatsinks, enclosures, and cooling solutions, working with Power and Embedded teams to ensure safe, reliable integration of mechanical and electrical subsystems.

You will design, simulate, prototype, test, and guide production-ready solutions that meet automotive/industrial standards and deliver performance under demanding

Qualifications

• B.Sc. or M.Sc. in Mechanical Engineering or equivalent.
• 5+ years of experience in mechanical design for high-power electronics or industrial/automotive systems.
• Strong expertise in thermal management for high-power applications.
• Experience with selecting and optimizing cooling solutions for demanding electrical systems.
• Experience with CAD (SolidWorks, Creo, or similar) and thermal/structural simulation tools (CFD, FEA).
• Knowledge of IEC, UL, automotive, rail standards.
• Proven ability to integrate mechanical and electrical designs in high-voltage systems.
• Hands-on, proactive, and capable of driving designs from concept to production.

Responsibilities

• Design and optimize thermal management systems, including heatsinks, heat pipes, cooling channels, and forced-air or liquid cooling solutions
• Select and tailor cooling solutions for each project to achieve optimal thermal performance
• Develop mechanical structures, enclosures, and busbar supports for high-voltage systems
• Collaborate with Power Electronics and Embedded teams to ensure integration of mechanical and electrical systems
• Perform thermal and structural simulations (CFD, FEA) to validate designs under operational conditions
• Define and oversee prototype manufacturing, assembly, and testing
• Ensure compliance with relevant standards and safety regulations for high-voltage and automotive/industrial systems

Skills

Thermal management

High-power electronics

Mechanical design

CAD

CFD/FEA

HV systems integration

Prototyping & testing

Education

B.Sc. or M.Sc. in Mechanical Engineering

Tools

SolidWorks

Creo

CFD/FEA software

Job description

Who Are We:

At Voltify, we are building the next generation of rail - battery locomotives that fast charge autonomously and dynamically through a dedicated self-sustained microgrid network.

We are bringing back the power to the industry and eliminating the dependency on fossil fuels.

Lowering the rail industries main expense - energy - by more than 20%.

This is over $3B yearly just in North America.

We are already working with some of the largest global rail companies with over $50M in contingent orders.

We have raised over $30M from top tier funds and strategics and rapidly growing.

Our founding team has a proven track record in building billion $ public companies in renewable energy and infrastructure.

About The Role:

We are looking for an experienced Mechanical Engineer to join our high-power electronics development team. You will play a key role in the design and optimization of mechanical and thermal solutions for high-voltage DC-DC converters, inverters, and busbars.

In this role, you will work closely with Power engineers, contributing the mechanical and thermal design of high-power systems. You will be responsible for designing heatsinks, enclosures, and cooling solutions that ensure reliability, safety, and performance under demanding electrical loads. You will also participate in prototype development, testing, and integration, ensuring seamless collaboration between mechanical and electrical subsystems.

This is a highly visible and impactful role where your designs will directly influence the performance, safety, and manufacturability of the company’s next-generation power electronics products. You will also ensure compliance with relevant standards and regulations, including automotive, industrial, and high-voltage requirements.

Responsibilities:

• Design and optimize thermal management systems, including heatsinks, heat pipes, cooling channels, and forced-air or liquid cooling solutions
• Select and tailor cooling solutions for each project to achieve optimal thermal performance
• Develop mechanical structures, enclosures, and busbar supports for high-voltage systems
• Collaborate with Power Electronics and Embedded teams to ensure integration of mechanical and electrical systems
• Perform thermal and structural simulations (CFD, FEA) to validate designs under operational conditions
• Define and oversee prototype manufacturing, assembly, and testing
• Ensure compliance with relevant standards and safety regulations for high-voltage and automotive/industrial systems

Qualification:

• B.Sc. or M.Sc. in Mechanical Engineering or equivalent
• 5+ years of experience in mechanical design for high-power electronics or industrial/automotive systems
• Strong expertise in thermal management for high-power applications
• Experience in selecting and optimizing cooling solutions for demanding electrical systems
• Experience with CAD (SolidWorks, Creo, or similar) and thermal/structural simulation tools (CFD, FEA)
• Knowledge of relevant standards (IEC, UL, automotive, rail)
• Proven ability to integrate mechanical and electrical designs in high-voltage systems
• Hands-on, proactive, and capable of driving designs from concept to production

Advantages:

• Experience in EV, rail (traction systems), or energy storage (BESS) - strong advantage
• Familiarity with automotive/ rail standards (e.g., ISO, LV standards, functional safety) – strong advantage
• Knowledge of insulation systems and HV reliability
• Experience with product lifecycle ownership (from concept to production)
• Experience working with global suppliers and subcontractors