Sr Engineer, Mechanical Design – High Voltage EV Systems

Socket.dev; Carlsbad (CA); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Stock option grants

Fully funded benefits for employee + 1

Flexible Time Away policy

Job summary

Socket.dev is seeking an experienced Mechanical Design Engineer to package 400–800 V EV components. You will craft compact enclosures for PCAs, busbars, and harnesses, ensuring thermal, dielectric, and EMI/EMC reliability. You’ll work with electrical and systems engineers to optimize layouts and supplier manufacturability.

The role requires 5+ years in HV mechanical packaging, a CATIA background, and hands-on assembly experience. Arcadia experience is a plus, with on-the-job learning available.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field.
• 5+ years of experience in mechanical packaging of HV EV components.
• Proficiency in 3D CAD (CATIA) and ability to deliver production-ready models.
• Familiarity with EMI/EMC design considerations in packaging.

Responsibilities

• Package high-voltage (400–800 V) automotive systems, including PCAs, busbars, harnesses, and power distribution units.
• Develop dense, compact layouts optimizing thermal performance and dielectric strength.
• Apply dielectric materials knowledge and creep considerations for safe, durable designs.
• Collaborate with electrical engineers on placement, routing, and packaging trade-offs.
• Incorporate EMI/EMC mitigation strategies into packaging solutions.
• Produce 3D CAD models and 2D drawings (CATIA preferred; Arcadia learning on the job).
• Support harness routing/packaging with Arcadia; participate in design reviews and supplier work.
• Hands-on assembly of designs to prove out concepts and create work instructions.

Skills

High-voltage packaging

3D CAD modeling

EMI/EMC design

Harness routing design

Dielectric materials knowledge

Education

Bachelor's degree in Mechanical Engineering

Tools

Arcadia

CATIA

Job description

About the role

We are seeking an experienced Mechanical Design Engineer with expertise in packaging high-voltage systems (400 V – 800 V) for electric vehicles. This role focuses on designing compact, reliable, and safe enclosures and packaging for circuit board assemblies, busbars, harnesses, and high-voltage components. You’ll work closely with electrical and systems engineers to ensure that mechanical packaging solutions meet demanding electrical, thermal, and safety requirements.

What you'll do

• Package high-voltage (400–800 V) automotive systems, including circuit board assemblies, busbars, harnesses, and power distribution units.
• Develop dense, compact layouts that optimize thermal performance, dielectric strength, clearances/creepage, and long-term reliability.
• Apply a working knowledge of dielectric properties of materials, thermal management, and material creep to ensure safe, durable designs.
• Collaborate with electrical engineers on component placement, routing, and packaging trade-offs.
• Incorporate EMI/EMC mitigation strategies into packaging solutions.
• Produce detailed 3D CAD models and 2D drawings (CATIA preferred; willingness to learn required).
• Support harness routing and packaging using Arcadia (or learn quickly on the job).
• Participate in design reviews and work closely with suppliers to ensure manufacturable solutions.
• Hands on assembly of the designs for proving out design and creating work instructions.

Qualifications

• Proven track record in packaging 400–800 V EV components (circuit board assemblies, busbars, harnesses, distribution units).
• Read and understand system schematics and wiring diagrams.
• Proficiency in 3D CAD tools (CATIA preferred) with ability to deliver production-ready models and drawings.
• Familiarity with EMI/EMC design considerations in packaging.
• Bonus: Experience with Arcadia harness design tool.

Team Structure

• Individual contributor; collaborate with other teams and individuals, as necessary

Required Experience

• 5+ years of experience in mechanical packaging of high-voltage systems for automotive or related industries

Educational Requirements

• Bachelor’s degree (or higher) in Mechanical Engineering or related field

Salary + Benefits

• Market competitive compensation package
• Stock option grants
• Fully funded benefits package for employee + dependents
• Generous Flexible Time Away policy