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