Senior Mechanical Engineer - Power Systems & Thermal Lead

LayerZero Power Systems, Inc.; Aurora (OH); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Dental insurance (no cost)

Vision insurance (no cost)

Short/Long-term disability (no cost)

Life insurance (no cost)

Medical plan options

Employee assistance program

Health savings account contributions

Retirement plan with employer match

Paid parental leave

Job summary

LayerZero Power Systems, Inc. seeks a Senior Mechanical Engineer to lead the structural, thermal, and manufacturing integration of next‑generation power systems. You will drive advanced FEA/CFD analyses, validate models, and optimize CAD for manufacturing, while mentoring junior engineers.

You will ensure safety, reliability, and compliance with industry standards for Static Transfer Switches and Power Distribution Units, participating in design reviews and RCA when needed.

Qualifications

• 5+ years of experience in mechanical design and simulation for electromechanical systems.
• Proficient with Solid Edge 3D CAD tooling.
• Expert in FEA and CFD.
• Design for manufacturability and reliability in sheet metal and electromechanical assemblies.
• Strong understanding of thermal management, structural mechanics, and vibration analysis.
• Hands-on thermal and vibration testing experience.
• PE license is highly desired.

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.
• Define parameters and provide technical support for 3rd-party testing to achieve industry certifications.
• Define and support internal product testing parameters for 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.

Skills

Mechanical design

FEA

CFD

3D CAD

Manufacturability

Thermal analysis

Vibration analysis

Field testing

Education

Bachelor’s or Master’s degree in mechanical engineering

PhD preferred

Tools

Solid Edge

Job description

LayerZero Power Systems, Inc. seeks a Senior Mechanical Engineer to lead the structural, thermal, and manufacturing integration of next‑generation power systems. You will drive advanced FEA/CFD analyses, validate models, and optimize CAD for manufacturing, while mentoring junior engineers.

You will ensure safety, reliability, and compliance with industry standards for Static Transfer Switches and Power Distribution Units, participating in design reviews and RCA when needed.