Staff Mechanical Engineer

Trystar; Waukesha (WI); On-site; USD 110,000 - 140,000; Full time

Job summary

Trystar is seeking a Staff Mechanical Engineer to lead mechanical design in power conversion solutions, coordinating large-scale engineering projects and mentoring teams across R&D and manufacturing.

The role emphasizes in-person collaboration at Merrimack, NH or Waukesha, WI, with responsibility for hardware design, packaging, and cross-functional support. Travel up to 20% within the USA and Canada is expected.

Qualifications

• Bachelor's degree in Mechanical Engineering or equivalent.
• 7+ years as a mechanical design engineer, preferably in power electronics packaging.
• Experience with power electronic system design (enclosures, panel layout, heat management) within electrical equipment, heavy industry, or military sectors.
• Proficiency with major ERP and CAD systems (SolidWorks or equivalent).
• Working knowledge of industry codes and standards: ASME, NEMA, UL, IEC.
• Proficient in generating and reviewing engineering documentation including BOMs and drawings for sheet metal, plastic, and extruded parts.
• Travel up to 20% within the USA and Canada.

Responsibilities

• Perform complete mechanical design, including layout, part/assembly modeling, drawings, and mechanical requirements definition.
• Support thermal analysis, FEA, and CFD simulations.
• Define, design, prototype, validate, and support mechanical systems (rack-mounted equipment, modular power devices, UPS, rectifiers, inverters).
• Lead mechanical design reviews and mentor across product lines.
• Collaborate with hardware design engineers for PCB mounting and packaging requirements.
• Develop 3D CAD models and drawings with complex surfaces and assemblies.
• Work with QA, Manufacturing, and Assembly to improve designs and manufacturability.
• Design and validate assembly and test fixtures; support prototypes and production launches.
• Manage BOMs and documentation using ERP/PDM tools.
• Address vendor questions on mechanical parts (change requests, obsolescence, substitutions).
• Document mechanical requirements and best practices for enclosures of power conversion systems.
• Contribute to standardizing design practices across sites.
• Provide technical mentorship to design engineers and technicians.

Education

Bachelor's degree in Mechanical Engineering

Seven (7) years of mechanical design experience

Tools

SolidWorks or equivalent

Job description

Job Title: Staff Mechanical Engineer - Merrimack, NH; or Waukesha, WI (onsite)

Job Description

Trystar is a leader in power inverters, distribution equipment, and related services at the heart of supporting our electrical infrastructure. Our team members focus on producing the highest quality products in the industry and providing industry-leading services. Safety and integrity are our guiding principles, and we work together to achieve excellence for our customers every day.

Trystar’s team members are our most important asset. W e are in search of a Staff Mechanical Engineer who will lead our design efforts in Power Conversion Solutions to exceed customer expectations & achieve strategic and aspirational growth plans while following our values & guiding principles.

In this role you will get to design and coordinate large-scale engineering designs in a rapidly growing and increasingly central portion of Trystar’s enterprise-wide business strategy. The successful candidate will be able to create new designs and advise on a course of action on preexisting projects. In this role, you will act as a trusted team-mate to our R&D, internal, and external stakeholders, ensuring that we are on time, adding value beyond what is being requested, all while providing the easiest path to a solution in the industry.

This position is preferably based in Merrimack, NH; or our Waukesha, WI location. It requires in-person presence in the office. You will be responsible for the design and development of new technology offerings within the Research, Development & Engineering – Power Conversion team.

We are looking for people who believe in our guiding principles and values of:

• Safety – We believe everyone should leave Trystar facilities in the same or better condition than when they arrived.
• Integrity – We’re honest, transparent, and committed to doing what’s right.
• Customer focus – We have relentless focus on our customers and their success.
• Right with speed – We use good judgement, make thoughtful decisions quickly, and execute them with purpose and intensity.
• Play for each other – We’re a team. We show up for each other and we know that through teamwork we achieve greatness.
• Champion change – We know adaptation and improvement are requirements to survive and to thrive.
• Enjoy the journey – We create an environment where our team feels appreciated and has fun along the way.

Job Responsibilities

• Perform complete mechanical design, including layout, part/assembly modeling, drawings, and mechanical requirements definition.
• Support advanced engineering analysis, including system-level thermal analysis, Finite Element Analysis (FEA), and Computation Fluid Dynamics (CFD) simulations.
• Define, design, prototype, validate, and support mechanical systems for products such as Rack-Mounted equipment, modular power devices, UPS’s, Rectifiers, Inverters, and more.
• Lead mechanical design reviews and provide technical guidance across multiple product lines at Trystar sites.
• Work with hardware design engineers to develop PCB mounting and packaging requirements.
• Develop detailed 3D CAD models and drawings, including complex surfaces, routed assemblies, and mechanical enclosures.
• Collaborate with cross-functional teams (QA, Manufacturing, Assembly) to improve product designs, documentation, and manufacturability.
• Design and validate assembly and test fixtures; support prototype builds and production launches.
• Manage BOMs, documentation for new and existing parts, using database tools (e.g., Empower, PDM, Epicor)
• Answer vendor questions regarding mechanical parts (change requests, obsolescence, substitution).
• Define and document mechanical requirements and best practices for enclosures of power conversion systems.
• Contribute to efforts to standardize design practices across sites.
• Provide technical mentorship and guidance to design engineers, test technicians, fabrication, and assembly personnel.

Job Requirements

Basic Qualifications

• Bachelor's degree in Mechanical Engineering or an equivalent
• Minimum seven (7) years of experience as a mechanical design engineer, preferably in power electronics design/packaging.
• Experience with power electronic system design (electrical enclosures, panel layout, seismic considerations, heat management) within electrical equipment, heavy industry, or military sectors.
• Proficiency with major ERP and CAD systems (SolidWorks or equivalent).
• Working knowledge of industry codes and standards: ASME standards, NEMA, UL, IEC, and other applicable standards within mechanical engineering discipline.
• Proficient in generating and reviewing engineering documentation including BOMs and detailed drawings for sheet metal, plastic, and extruded parts.
• Proficient with Microsoft Office applications and Microsoft Cloud services.
• Travel up to 20% within the USA and Canada.

Additional Qualifications

• Experience with UL 1741, CSA C22.2, and others.
• Strong communications skills (oral, written, and presentation) with the ability to influence across all levels of the organization, including in-person and remote interactions.
• Ability to adapt & thrive in a fast-paced/evolving work environment.
• Professional Engineer (PE) license is a plus.
• Ability to excel working as the sole mechanical engineer on a project.
• Ability to create project requirements from incomplete inputs.
• Strong understanding of structural and thermal analysis (FEA/CFD tools such as SolidWorks (Flow) Simulation, ANSYS, COMSOL, or similar).