{"id":3950996,"url":"https://alion.io/job/layerzero-power-systems-senior-mechanical-engineer","title":"Senior Mechanical Engineer","company":{"id":4474307,"name":"LayerZero Power Systems","domain":"layerzero.com","url":"https://alion.io/company/layerzero-power-systems","size_band":"51-200","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Schema","truth_index":null},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Aurora, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":null,"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"LayerZero","optional":false}],"status":"live","first_seen_at":"2026-11-03T16:34:16Z","employer_posted_date":"2026-11-03","last_verified_at":"2026-11-09T20:49:18Z","board_verified":true,"closed_at":null,"days_open":6,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":6},"description":"Overview\n***THIS IS AN ON-SITE POSITION LOCATED IN AURORA, OHIO***\nAbout Us:\nLayerZero 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.\nPosition Description: Senior Mechanical Engineer\nWe 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.\nRequirements\nPrimary Duties:\nLead mechanical design and analysis activities for power systems products including Static Transfer Switches and Power Distribution Units.\nDrive mechanical and thermal design by performing advanced FEA and CFD simulations.\nValidate analytical models through calculation, prototype testing and measurement.\nOptimize 3D CAD models specifically for our vertically integrated manufacturing capabilities.\nSupport sustaining engineering efforts to improve existing product designs.\nEmbed industry standards into the physical geometry, ensuring operator safety and clearance constraints are fundamental design inputs rather than post-design checks.\nDefine the parameters and provide technical support for 3rd-party testing to achieve and maintain industry certifications.\nDefine and support internal product testing parameters for both prototypes and final production units.\nContribute to rigorous design reviews, establish internal engineering standards, and coach junior engineers in advanced analysis techniques.\nLead Root Cause Analysis (RCA) and provide high-level technical resolution for complex field support issues.\nExperience & Skills:\n5+ years of experience in mechanical design and simulation for electromechanical systems.\nExperience with 3-D CAD tools (Solid Edge preferred) -- Required.\nExpert in FEA and CFD.\nProven experience with design for manufacturability and design for reliability in sheet metal and electro-mechanical assemblies.\nStrong understanding of thermal management, heat transfer, structural mechanics, and vibration analysis.\nHands-on experience with thermal and vibration testing.\nFamiliarity with electrical power systems is a strong plus.\nKnowledge of NFPA 70, UL, IEC, CSA, NOM or ANSI standards for power equipment.\nExcellent communication and documentation skills.\nAn active Professional Engineer (PE) License is highly desired.\nEducation:\nBachelor’s or Master’s degree in mechanical engineering or related field (PhD preferred).\nWhy Join Us? Our Benefits Make a Difference.\nWe 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.\n$0 cost Dental Insurance \n$0 cost Vision Insurance \n$0 cost Short Term and Long-Term Disability Insurance \n$0 cost Life Insurance with additional buy up options \nMedical Plan Choices, including one no cost medical option plus two additional buy up plan options \n$0 cost Employee Assistance Program offering confidential counseling and support services \nEmployer Health Savings Account Contributions to help offset health expenses \nRetirement Plan Options with generous employer matching contributions \nPaid Parental Leave to support your growing family \nWhy You Will Love Working with Us\nImpact: Develop your skills and expertise in a rapidly growing industry, with your work directly influencing the success of mission critical projects. \nInnovation: Immerse yourself in an environment that celebrates forward thinking and continuous improvement. \nCollaborative Spirit: Work closely with engineers, marketers, and other professionals to bring ideas to life. \nGrow With Us: We are committed to your personal and professional development, offering endless opportunities to improve your skills and advance your career. \nAt LayerZero, we are proud to be an Equal Opportunity Employer. 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