Senior Mechanical Engineer
Confirmed on the employer's own hiring board on Nov 9, 2026. First seen by Alion on Nov 3, 2026.
Overview
***THIS IS AN ON-SITE POSITION LOCATED IN AURORA, OHIO***
About Us:
LayerZero Power Systems LLC. is a globally recognized leader in providing state-of-the-art power distribution solutions for critical industries. With a strong focus on reliability, innovation, and customer satisfaction, we deliver advanced power systems products that ensure uninterrupted and dependable power supply in mission-critical environments. Our customer base is comprised of companies in the data center (our main focus), financial, computer service provision, and semiconductor manufacturing sectors. LayerZero Power Systems is on a trajectory of sustained growth, with a loyal customer base of existing Fortune 100 customers and an expanding portfolio of new customers.
Position Description: Senior Mechanical Engineer
We are seeking a Senior Mechanical Engineer with a mastery of first principles engineering to lead the structural, thermal, and manufacturing integration of next-generation power systems products. The ideal candidate will play a key role in solving complex technical challenges, ensuring every design is validated, optimized, and built to deliver uncompromising, long-term reliability for our Static Transfer Switches and Power Distribution Units.
Requirements
Primary Duties:
- Lead mechanical design and analysis activities for power systems products including Static Transfer Switches and Power Distribution Units.
- Drive mechanical and thermal design by performing advanced FEA and CFD simulations.
- Validate analytical models through calculation, prototype testing and measurement.
- Optimize 3D CAD models specifically for our vertically integrated manufacturing capabilities.
- Support sustaining engineering efforts to improve existing product designs.
- Embed industry standards into the physical geometry, ensuring operator safety and clearance constraints are fundamental design inputs rather than post-design checks.
- Define the parameters and provide technical support for 3rd-party testing to achieve and maintain industry certifications.
- Define and support internal product testing parameters for both prototypes and final production units.
- Contribute to rigorous design reviews, establish internal engineering standards, and coach junior engineers in advanced analysis techniques.
- Lead Root Cause Analysis (RCA) and provide high-level technical resolution for complex field support issues.
Experience & Skills:
- 5+ years of experience in mechanical design and simulation for electromechanical systems.
- Experience with 3-D CAD tools (Solid Edge preferred) -- Required.
- Expert in FEA and CFD.
- Proven experience with design for manufacturability and design for reliability in sheet metal and electro-mechanical assemblies.
- Strong understanding of thermal management, heat transfer, structural mechanics, and vibration analysis.
- Hands-on experience with thermal and vibration testing.
- Familiarity with electrical power systems is a strong plus.
- Knowledge of NFPA 70, UL, IEC, CSA, NOM or ANSI standards for power equipment.
- Excellent communication and documentation skills.
- An active Professional Engineer (PE) License is highly desired.
Education:
- Bachelor’s or Master’s degree in mechanical engineering or related field (PhD preferred).
Why Join Us? Our Benefits Make a Difference.
We believe great employees deserve great benefits designed to support health, financial well-being, professional growth, and family needs. Most of our core benefits are provided at no cost, reflecting our commitment to investing in the well-being of our team.
- $0 cost Dental Insurance
- $0 cost Vision Insurance
- $0 cost Short Term and Long-Term Disability Insurance
- $0 cost Life Insurance with additional buy up options
- Medical Plan Choices, including one no cost medical option plus two additional buy up plan options
- $0 cost Employee Assistance Program offering confidential counseling and support services
- Employer Health Savings Account Contributions to help offset health expenses
- Retirement Plan Options with generous employer matching contributions
- Paid Parental Leave to support your growing family
Why You Will Love Working with Us
- Impact: Develop your skills and expertise in a rapidly growing industry, with your work directly influencing the success of mission critical projects.
- Innovation: Immerse yourself in an environment that celebrates forward thinking and continuous improvement.
- Collaborative Spirit: Work closely with engineers, marketers, and other professionals to bring ideas to life.
- Grow With Us: We are committed to your personal and professional development, offering endless opportunities to improve your skills and advance your career.
At LayerZero, we are proud to be an Equal Opportunity Employer. We welcome and celebrate diversity, and we are committed to creating an inclusive environment for all employees.