Senior Mechanical Design Engineer

The posted salary range reflects compensation for our Newark, CA office. This role requires employees to be onsite five days a week.

We are seeking an experienced Senior Mechanical Design Engineer who will be responsible for designing, developing, and validating mechanical systems and enclosures for Advanced Driver-Assistance Systems (ADAS) system and other ECUs working with third-party suppliers. The ideal candidate will have a strong mechanical engineering background, expertise in automotive electronic packaging, and proven experience delivering innovative designs from concept to production.

Key Responsibilities:

• Design and develop robust mechanical enclosures and brackets for ECU systems, ensuring accurate thermal management, and protection against environmental factors (e.g., vibration, shock, thermal cycling).
• Collaborate closely with electrical engineering teams to optimize ECU housing designs, ensuring appropriate integration with electronic components, PCBs, and wiring harnesses.
• Perform detailed 3D modeling and drafting using CATIA (V5 or V6) CAD software.
• Conduct comprehensive tolerance stack-up analyses and apply GD&T principles to ensure manufacturing feasibility, functionality, and assembly accuracy.
• Execute thermal, structural, and vibration simulations using CAE tools such as Ansys to validate designs against automotive industry standards.
• Develop and oversee mechanical testing protocols, including shock, vibration, and thermal cycling, to confirm system robustness and reliability.
• Evaluate and select appropriate materials and manufacturing processes (e.g., injection molding, die-casting, sheet metal stamping) to optimize quality, performance, manufacturability, and cost-efficiency.
• Collaborate with suppliers and internal production teams to ensure designs are production-ready and support smooth transition into high-volume manufacturing.
• Identify, troubleshoot, and resolve mechanical design issues in existing and prototype ECU products, driving continuous improvement in performance, reliability, and manufacturability.
• Prepare comprehensive technical documentation, including Bill of Materials (BOM), detailed assembly drawings, and mechanical design specifications.
• Participate actively in cross-functional meetings, effectively communicating design progress, risks, and improvement recommendations.

Qualifications:

• Bachelor's degree in Mechanical Engineering or similar technical field is required.  
• 5+ years of mechanical design experience, specifically within automotive electronic component packaging.
• Strong proficiency in CATIA V5 or V6 CAD software.
• Proven expertise in automotive design standards, ASME GD&T, and tolerance stack-up analyses.
• Hands-on experience with plastic injection molding, sheet metal stamping, and die-casting manufacturing processes.
• Demonstrated knowledge of thermal management, structural integrity, vibration isolation, and EMC compliance in automotive electronic systems.
• Proficiency in CAE analysis tools, particularly Ansys, for thermal, mechanical, and vibration simulations.
• Excellent problem-solving skills, first-principles thinking, and analytical abilities.
• Effective communication and collaboration skills, capable of working cross-functionally within multidisciplinary teams.

Preferred Qualifications:

• Familiarity with automotive harnessing, electrical integration, and vehicle-level packaging constraints.
• Experience working with Tier 1 automotive suppliers and OEM manufacturing processes.
• Knowledge of automotive industry standards and certifications (e.g., UL, ISO, RoHS).
• Master’s degree or higher education is preferred.

Join us in shaping the future of mobility by contributing your mechanical design expertise to groundbreaking technologies.