Senior Electromechanical Engineer
Location: Sterling, VA
Position: Full-Time, On-Site
Position Summary We are seeking a Senior Electromechanical Engineer to design and develop enclosures, power cabinets, control panels, and mechanical assemblies for electronic and power-electronic systems. The ideal candidate will have strong experience with SolidWorks, sheet-metal design, injection-molded parts, thermal analysis, and the mechanical integration of electrical and power-system components.
Key Responsibilities - Design electrical enclosures, power cabinets, control panels, chassis, racks, and related mechanical assemblies.
- Develop electromechanical packaging solutions for electronic and power-electronic products.
- Integrate PCBs, busbars, breakers, contactors, transformers, power supplies, connectors, cooling components, wiring, and grounding into mechanical designs.
- Create 3D models, production drawings, assemblies, and bills of materials using SolidWorks.
- Perform thermal calculations and simulations, including airflow analysis, fan sizing, heat-sink selection, and natural or forced-air cooling.
- Design sheet-metal parts, welded structures, brackets, doors, covers, mounting systems, and injection-molded plastic components.
- Define mechanical and electrical interfaces, cable routing, strain relief, service access, assembly requirements, and component mounting.
- Ensure appropriate electrical clearances, creepage distances, insulation, ventilation, EMI shielding, grounding, vibration resistance, and thermal separation.
- Apply GD&T, tolerance analysis, material selection, and design-for-manufacturing and assembly principles.
- Support prototype builds, thermal and mechanical testing, design validation, troubleshooting, and product certification.
- Work closely with Electrical, Power Electronics, PCB, Manufacturing, and Product Engineering teams.
- Coordinate with sheet-metal, machining, molding, and manufacturing suppliers from concept through production.
Required Qualifications - Bachelor's degree in Mechanical Engineering, Electromechanical Engineering, or a related field.
- At least 7 years of mechanical product-design experience.
- Advanced proficiency in SolidWorks, including Sheet Metal, Weldments, assemblies, and detailed drawings.
- Experience designing electrical enclosures, cabinets, electronic equipment, or power-electronic products.
- Strong knowledge of sheet-metal fabrication and injection-molded plastic design.
- Experience with thermal modeling, airflow analysis, and cooling of electronic or power-electronic systems.
- Practical understanding of electrical components, wiring, connectors, cable management, grounding, and electromechanical packaging.
- Working knowledge of power systems, including high-voltage equipment, busbars, breakers, contactors, transformers, and electrical safety.
- Knowledge of GD&T, tolerance analysis, and design for manufacturing and assembly.
- Strong communication, problem-solving, and cross-functional collaboration skills.
Preferred Qualifications - Experience with SolidWorks Flow Simulation, ANSYS Icepak, FloEFD, or similar thermal-analysis software.
- Experience with power converters, power-distribution equipment, UPS systems, battery systems, or data-center power products.
- Familiarity with NEMA, UL, IEC, IP-rating, thermal, vibration, and environmental requirements.
- Experience developing products from initial concept through prototype, testing, certification, and production.
Benefits- Competitive salary and performance bonus
- Paid time off
- 401(k) retirement plan with company match
- Comprehensive health, dental, and vision insurance
- Collaborative, high-energy workplace
Our Core Values- Safety - We proactively protect our people and environment
- Inclusion - We respect and appreciate diverse perspectives and backgrounds
- Speed - We move fast, act decisively, and stay agile
- Innovation - We challenge assumptions and simplify processes
- Judgment - We make sound decisions with the business in mind
- Accountability - We take ownership and deliver results
Physical Demands and Work EnvironmentEmployees must be able to hear, speak, and communicate effectively. Work occurs in data center environments with potential exposure to electrical hazards, noise, and varying temperatures. Flexible hours, including nights and weekends, may be required. Physical requirements include bending, stooping, squatting, crawling, climbing, kneeling, balancing, pushing, pulling, and reaching overhead. Must lift at least 50 lbs and work at heights up to 90 ft using ladders, scaffolds, or lifts.
