Senior Mechanical Engineer - RF & Thermal Systems Lead

Advanced Energy; Colorado; On-site; USD 120,000 - 180,000; Full time

Job summary

Advanced Energy in Fort Collins, CO, 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.

You will drive thermal management, material selection, and manufacturability, mentor junior engineers, and collaborate with electrical, RF, and reliability teams to deliver high-power solutions. This role shapes next-generation plasma power solutions.

Qualifications

• Expert proficiency in SolidWorks or equivalent 3D CAD software.
• Advanced knowledge of tolerance analysis and GD&T (ANSI Y14.5).
• Strong hands-on experience with lab testing, instrumentation, and data analysis.
• Ability to self-manage projects from concept to release, including schedule and cost control.
• Proficiency with Ansys, COMSOL, or similar simulation tools.
• Background in electronics packaging, RF systems, or high-power applications.

Responsibilities

• Lead mechanical engineering efforts across all product development phases.
• Architect and optimize thermal management systems including cold plates, heat exchangers, and active cooling solutions.
• Perform advanced simulations (thermal, structural, fluid flow) using tools like 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.
• Collaborate with suppliers and internal teams to ensure manufacturability, cost-effectiveness, and supply chain resilience.
• Mentor junior engineers and contribute to technical reviews, design standards, and best practices.
• Interface with customers and OEMs to define and negotiate mechanical design requirements.

Skills

SolidWorks

Tolerance analysis & GD&T

Lab testing & data analysis

Project management

RF/high-power electronics background

Tools

Ansys

COMSOL

Job description

Advanced Energy in Fort Collins, CO, 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.

You will drive thermal management, material selection, and manufacturability, mentor junior engineers, and collaborate with electrical, RF, and reliability teams to deliver high-power solutions. This role shapes next-generation plasma power solutions.