Senior Mechanical Engineer, High-Power Thermal Design

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

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