About the roleThe Enphase Power Systems Innovation team in the CTO's office is responsible for defining, prototyping, and supporting Enphase's Solid State Transformer products. The team is an integrated, multi-disciplinary group looking for motivated individuals who can contribute and collaborate closely with the team to deliver innovative solutions. As a team member, you will solve some of the most exciting problems in the energy space and help shape the direction of our products. We are looking for a Mechanical Design Engineer with a strong background in the mechanical design and integration of electrical equipment - including busbars, wire harnesses, electronic board packaging, and connectors - who will own the integration of the support and control system for Enphase's first-generation Solid State Transformer product.
What You Will Do- Design high-current busbar assemblies - including conductor sizing, layout routing, thermal management, and mechanical mounting
- Own wire harness design and routing, including connector selection, terminal specification, cable management, strain relief, and harness drawing packages
- Design electronic board packaging solutions - including enclosures, mounting hardware, EMI shielding, thermal interface management, and serviceability provisions
- Specify and design electrical connectors and interconnect systems, ensuring reliable mating, adequate current ratings, and compatibility with assembly and service workflows
- Perform electrical insulation coordination for internal mechanical components, including creepage and clearance analysis, material selection for dielectric performance, and compliance with relevant voltage class requirements
- Ensure field-replaceable boards are accessible and documented with clear service procedures
- Ensure the design is manufacturable- selecting appropriate fabrication methods, tolerancing for producibility, and collaborating with contract manufacturing partners to ensure smooth production ramp
- Perform structural and thermal analysis (hand calculations and FEA/CFD) on busbars, mounting structures, and packaging assemblies to validate performance under rated and fault conditions
- Produce 2D drawings and 3D CAD models, evaluate parts, and collaborate with internal stakeholders, suppliers, and contract manufacturing partners to bring your design to market
- Specify key functional and performance requirements; design and execute verification test plans
- Complete documentation for design, testing, and analysis
- Hands-on fabrication of electromechanical assemblies and prototypes
- Mentor junior staff
Who You Are and What You Bring- Staff Engineer: BS + 8 yrs MS + 6 yrs PhD + 3 yrs
- Ability to solve problems independently and work effectively on early-stage product development efforts with ambiguous requirements and tasks
- Ability to take ownership of development tasks and manage various high-importance tasks simultaneously
- Significant experience in the mechanical design and integration of electrical support equipment for power electronics, power conversion, or analogous high-power electrical products
- Strong proficiency in busbar design - conductor sizing, laminated busbar stack-ups, insulation systems, thermal rise calculations, and mechanical mounting methods
- Demonstrated experience in wire harness design - routing, connector and terminal selection, wire gauge specification, and harness drawing creation
- Experience designing mechanical packaging for electronic boards, including thermal management, shock and vibration isolation, EMI considerations, and board-level interconnects
- Expertise in electrical insulation coordination - creepage and clearance analysis per IEC 60664-1 or equivalent, selection of insulating materials, and design practices for medium-voltage (>1 kV) environments
- Strong understanding of connector systems for power and signal applications - contact ratings, environmental sealing, keying, and mating cycle durability
- Demonstrated ability to design for manufacturing - tolerance analysis, process selection (sheet metal fabrication, CNC machining, injection molding, stamping, die casting), and close collaboration with manufacturing partners
- Expertise in various joining techniques such as welding, adhesives, riveting, fastened joints, and press-fit connections
- High proficiency with an enterprise CAD package (SolidWorks preferred)
- Good communication and documentation skills
- Strong hands-on mechanical prototyping skills
Additional Desired Skills- Proficiency with FEA/CFD simulation (thermal, structural, electromagnetic)
- Experience with high-voltage (>1 kV) power conversion or switchgear equipment
- Familiarity with common standards for electrical equipment (UL, IEC, NEMA, IEEE)
- Experience with thermal management of power electronics assemblies (heat sink design, airflow path design, thermal interface materials, CFD)
- Familiarity with EMC/EMI design practices for power electronics packaging
- Experience with laminated or flexible busbar design and fabrication
Work LocationAustin, TX
The base pay range for this position is $100,000 to $151,000 per year. This salary range may be modified in the future. The successful candidate's starting pay will be determined based on job-related skills, experience, education or training, work location, and market conditions. This position is also eligible for bonus, equity, and benefits.
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