Senior Mechanical Engineer, RF Power & Thermal Systems

Advanced Energy Industries, Inc; Fort Collins (CO); On-site; USD 130,000 - 200,000; Full time

Benefits offered by this job

Medical plans

Disability & life insurance

Health savings and flexible spending

3 weeks paid vacation

7 days paid sick time

12 paid holidays

Volunteer time off

401(k)

Tuition reimbursement

Mental health coverage

Employee assistance program

Job summary

Advanced Energy 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 applications.

You will drive innovation in thermal management, materials selection, and mechanical design for high‑power electronics, mentor junior engineers, and collaborate across electrical, RF engineering, supply chain and product management to ensure manufacturability and reliability.

Qualifications

• Bachelor’s degree in mechanical engineering required, MS/PhD preferred.
• 10 years of mechanical engineering experience.
• Experience designing and validating thermal management systems.
• Experience with BOMs and configuration control in a multi‑product environment.
• Background in electronics packaging, RF systems, or high‑voltage/high‑power applications preferred.

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 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.

Skills

SolidWorks proficiency

Lab testing

Data analysis

Project management

GD&T understanding

Education

Bachelor’s degree in mechanical engineering

MS or PhD preferred

Tools

SolidWorks

Ansys

COMSOL

Job description

Advanced Energy 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 applications.

You will drive innovation in thermal management, materials selection, and mechanical design for high‑power electronics, mentor junior engineers, and collaborate across electrical, RF engineering, supply chain and product management to ensure manufacturability and reliability.