Mechanical Engineer Military Power Electronics - Burlington, Vermont 05403 ( 50% remote)

Candidates who have designed high-power electrical equipment, ruggedized enclosures, or defense-related products and supported those designs through testing and production are particularly encouraged to apply. You will work closely with electrical engineering, manufacturing, quality, supply chain, and customers to develop reliable products that meet thermal, structural, manufacturability, performance, and customer requirements.

Title: Mechanical Engineer – Military Power Electronics
Location: Burlington, Vermont 05403 ( 50% remote)
Job Type: Full-Time, Direct Hire

Position Overview
Sensata Technologies' Dynapower division is seeking an experienced Mechanical Engineer to support the development of next-generation military power conversion products. This role will lead mechanical design activities and support product development programs from initial concept through prototype development, testing, validation, and production.
The ideal candidate will have experience designing complex mechanical systems, particularly in power electronics, high-power energy systems, defense, military hardware, or other demanding engineering environments.
You will work closely with electrical engineering, manufacturing, quality, supply chain, and customers to develop reliable products that meet thermal, structural, manufacturability, performance, and customer requirements.
This is an excellent opportunity to work on advanced military power products and collaborate with an on-site engineering team where you can see the equipment being built and tested at the facility.
 
Key Responsibilities

• Lead mechanical design and development activities for complex power conversion products and assemblies.
• Develop and release production-ready engineering drawings, specifications, and technical documentation.
• Perform mechanical packaging and enclosure design, considering thermal management, structural integrity, and manufacturability.
• Support new product development (NPD) programs from concept and design through prototyping, validation, and production.
• Apply GD&T, tolerance analysis, and engineering best practices to ensure design accuracy and product reliability.
• Participate in prototype builds, product testing, design verification, and troubleshooting activities.
• Support engineering analysis, including thermal, structural, vibration, and finite element analysis (FEA), as applicable.
• Identify design issues, perform root cause analysis, and implement corrective actions.
• Collaborate with electrical engineering, manufacturing, quality, and supply chain teams to ensure successful product development and production readiness.
• Participate in technical discussions with customers and support design reviews, including Preliminary Design Reviews (PDR) and Critical Design Reviews (CDR).
• Ensure mechanical designs meet applicable customer, industry, and military requirements.

 
Required Qualifications

• Proven experience in mechanical design and development of complex hardware or electromechanical products.
• Experience with product development from concept through production.
• Experience creating engineering drawings, specifications, and production documentation.
• Proficiency with SolidWorks and PDM/EPDM or equivalent CAD and product data management tools.
• Strong knowledge of Geometric Dimensioning and Tolerancing (GD&T) and tolerance analysis.
• Experience with prototype development, product testing, validation, and design troubleshooting.
• Exposure to FEA, thermal management, vibration, or structural analysis.
• Experience collaborating with cross-functional engineering and manufacturing teams.
• Strong problem-solving, technical communication, and documentation skills.

 
Preferred Qualifications

• Experience developing defense, military, or other ruggedized hardware products.
• Familiarity with Department of Defense (DoD) product development requirements.
• Experience with naval or shipboard electrical systems and NAVSEA-related requirements.
• Background in power electronics packaging, high-power energy conversion systems, power distribution equipment, or medium-voltage products.
• Experience with thermal management and mechanical enclosure design for high-power equipment.
• Participation in PDRs, CDRs, design verification activities, and customer design reviews.
• Experience supporting manufacturing, prototype builds, and new product introduction (NPI).
• Ability to balance electrical integration, mechanical packaging, thermal performance, structural requirements, and manufacturability.

 
Ideal Candidate Profile
The strongest candidate will combine hands-on mechanical design ownership with experience in complex power electronics or military hardware. Candidates who have designed high-power electrical equipment, ruggedized enclosures, or defense-related products and supported those designs through testing and production are particularly encouraged to apply.