Senior Mechanical Engineer, Design and Thermal Analyses

Job Title: Senior Mechanical Engineer, Design and Thermal Analyses

Job Description:

Trystar develops power equipment through cross-functional engineering and manufacturing collaboration. You will connect practical mechanical design with test-grounded thermal analysis to help teams deliver reliable products.

This hands-on role combines mechanical requirements, design, packaging, CAD, and drawings with independent thermal and fluid modelling, prototype validation, test correlation, and manufacturing handoff. Your assignments support platform development, including power converters, switchboards, and load banks. The opportunity is to develop manufacturable equipment and apply rigorous thermal evaluations to higher power density within limited footprints, not to work exclusively on one product.

You report to a Senior Engineering Manager for RDE Power Distribution, who prioritizes assignments and resolves conflicting project demands. You work as a senior individual contributor, contribute technical mentoring, and support established release decisions; the role does not carry independent product release authority or automatic leadership of all products across sites.

In this role you will:

• Own the mechanical design of assigned products from requirements through preparation of finished-product release packages. Translate requirements into product packaging, part and assembly models, CAD layouts, production drawings, and other controlled mechanical artifacts, with clear ownership of mechanical decisions under established release authority.
• Develop enclosures and assemblies using appropriate materials and processes, including sheet metal, plastics, and extrusions. Design for safety, reliability, manufacturability, serviceability, and reuse across product platforms.
• Coordinate PCB mounting, structural interfaces, access, serviceability, and electrical packaging with electrical and power conversion engineers while maintaining distinct mechanical and electrical design ownership.
• Independently develop and interpret thermal and fluid models, including computational fluid dynamics where appropriate. Define assumptions, boundary conditions, operating cases, acceptance limits, and uncertainty before drawing conclusions, and explain the limitations of each result.
• Evaluate air, liquid, immersive, and thermosiphon cooling concepts as applicable. Analyze component temperatures, heat dissipation, flow, and power density within constrained footprints, and convert the results into explicit design decisions.
• Design and integrate thermal-management components, including cold plates, heat exchangers, busbars, pumps, fans, and thermal control loops. Work with electrical and compliance teams to define an effective power path and manage high-power heat loads.
• Lead cross-functional mechanical design reviews for assigned work. Assess DFM, assembly, maintenance access, design robustness, FMEA, AFMEA, IP ratings, seismic requirements, harsh-environment requirements, and other applicable equipment, product, and safety standards.
• Support NRTL construction reviews and the established design and release process by preparing design packages and objective evidence that the design meets applicable requirements.
• Plan and support prototype builds and validation with the testing team. Design test fixtures; perform required thermal, flow, HALT, vibration, and shock testing; and correlate measured temperatures, flow, and other responses with analytical predictions.
• Investigate simulation and test discrepancies, document their causes and resolution, and use the evidence to refine designs before manufacturing handoff.
• Prepare complete manufacturing work packages, including bills of materials, drawings, build guidance, and controlled technical documentation in the applicable product data management and release systems.
• Partner with Quality, Manufacturing, Sourcing, and suppliers to resolve assembly and field issues, evaluate new materials and production methods, manage supplier changes, obsolescence, and substitutions, and introduce automation and rapid prototyping where they improve execution.
• Build reusable platform designs and validated analysis methods rather than isolated solutions, increasing development speed and improving product performance across Trystar’s portfolio.
• Represent Trystar at technical conferences and build productive relationships with academic institutions and external technical partners.

Qualifications:

Required qualifications include a bachelor’s degree in mechanical engineering or an accepted equivalent from an accredited program and at least 7 years of relevant experience. You must demonstrate hands-on mechanical design, packaging, CAD models and drawings; independent thermal and fluid modelling and interpretation; physical test correlation and prototype validation; controlled technical documentation; and effective cross-functional communication. Your work must clearly define assumptions, boundary conditions, operating cases, acceptance limits, uncertainty, and unresolved discrepancies.

Preferred experience includes power electronics, high-power equipment, or load banks; structural finite element analysis and advanced cooling methods where applicable; and manufacturing processes, applicable equipment standards, and controlled product-release systems. These preferences do not replace the required capabilities. Equivalent CAD and analysis software is acceptable; no specific software brand, certification, or license is mandatory.

Skills:

Technical skills include mechanical design and drafting; product packaging; computational fluid dynamics and other thermal and fluid modelling; finite element analysis where applicable; SolidWorks or equivalent CAD software; prototype testing; and correlation of simulation results with physical measurements.

You communicate technical reasoning clearly, make design decisions from evidence, and work effectively with electrical engineering, power conversion engineering, testing, Quality, Manufacturing, and Sourcing. You connect simulation results to practical design changes and communicate uncertainty without obscuring risk. You may mentor colleagues technically; this role has no formal people management responsibilities.

Success means delivering accepted mechanical work packages against agreed milestones; verifying thermal performance against agreed operating conditions, footprint constraints, and component limits; documenting simulation and test agreement with discrepancies resolved; and developing reusable, validated platform designs and analysis methods. Key stakeholders will establish the numerical acceptance thresholds and milestone dates.

The role is hybrid at any Trystar site, including Burnsville, MN; Faribault, MN; Houston, TX; Charlotte, NC; Troy, MI; Merrimack, NH; Pointe-Claire, QC; and Victoria, BC. Travelling may account for up to 20% of the role within the United States and Canada. On-site frequency remains to be established; the hybrid arrangement does not imply a remote-only option.