Lead Mechanical Engineer - Electric Vehicle Power Electronics

Lead Mechanical Engineer As a Lead Mechanical Engineer, you will be part of Ford’s Global Advanced Product Development team, working on critical systems such as onboard chargers, DC/DC converters, battery management systems, and motor controllers. You will collaborate with cross-functional teams to design, prototype, validate, and deliver mechanical solutions for high-voltage power electronics in electric vehicles. This role offers the opportunity to work on cutting-edge technologies and influence designs that reach global production. Design and develop mechanical components and assemblies for EV power electronics systems, ensuring performance, cost, and reliability targets are met Collaborate with electrical, manufacturing, testing, and quality teams to ensure design-for-excellence (manufacturability, reliability, serviceability) Develop and validate prototypes using rapid prototyping techniques Work closely with suppliers from concept to production to ensure material and process feasibility Support product validation through test planning, execution, and documentation Identify and resolve manufacturing and quality issues using structured problem-solving methods (e.g., FMEA, root cause analysis) Support development of assembly processes and test fixtures Review engineering simulations (FEA) and incorporate improvements into designs Mentor junior engineers and contribute to technical reviews Must-Have Bachelor’s degree in Mechanical Engineering or related field 8+ years of experience in electromechanical product design for high-volume manufacturing Strong understanding of: GD&T (Geometric Dimensioning & Tolerancing) Tolerance stack-up analysis Design for manufacturing (DFM) across casting, machining, and plastics Plastic product design expertise Experience with PLM tools (e.g., Teamcenter or similar) Proficiency with CAD tools such as CATIA V6 / 3DEXPERIENCE Experience in prototyping, testing, and production release Nice-to-Have Master’s degree or certification in tool design (e.g., GTTC, NTTF) Experience in high-voltage electronics packaging Experience in EV systems (OBC, DC/DC converters, EV charging systems) Experience working with global suppliers Experience Level Senior Level