Sr Engineer, Mechanical Design – High Voltage EV Systems Carlsbad, California | Engineering | Full-time About the role We are seeking an experienced Mechanical Design Engineer with expertise in packaging high-voltage systems (400 V – 800 V) for electric vehicles. This role focuses on designing compact, reliable, and safe enclosures and packaging for circuit board assemblies, busbars, harnesses, and high-voltage components. You’ll work closely with electrical and systems engineers to ensure that mechanical packaging solutions meet demanding electrical, thermal, and safety requirements. What you'll do • Package high-voltage (400–800 V) automotive systems, including circuit board assemblies, busbars, harnesses, and power distribution units. • Develop dense, compact layouts that optimize thermal performance, dielectric strength, clearances/creepage, and long-term reliability. • Apply a working knowledge of dielectric properties of materials, thermal management, and material creep to ensure safe, durable designs. • Collaborate with electrical engineers on component placement, routing, and packaging trade-offs. • Incorporate EMI/EMC mitigation strategies into packaging solutions. • Produce detailed 3D CAD models and 2D drawings (CATIA preferred; willingness to learn required). • Support harness routing and packaging using Arcadia (or learn quickly on the job). • Participate in design reviews and work closely with suppliers to ensure manufacturable solutions. • Hands on assembly of the designs for proving out design and creating work instructions. Qualifications • Proven track record in packaging 400–800 V EV components (circuit board assemblies, busbars, harnesses, distribution units). • Read and understand system schematics and wiring diagrams. • Proficiency in 3D CAD tools (CATIA preferred) with ability to deliver production-ready models and drawings. • Familiarity with EMI/EMC design considerations in packaging. • Bonus: Experience with Arcadia harness design tool. Team Structure • Individual contributor; collaborate with other teams and individuals, as necessary Required Experience • 5+ years of experience in mechanical packaging of high-voltage systems for automotive or related industries Educational Requirements • Bachelor’s degree (or higher) in Mechanical Engineering or related field Salary + Benefits • Market competitive compensation package • Stock option grants • Fully funded benefits package for employee + dependents • Generous Flexible Time Away policy
See More Details >>For more than six decades, the skilled thinkers, makers, and doers at Frontgrade have embraced our mission to solve complex technology challenges across the U.S. and around the globe. We’re the leading provider of high reliability and radiation assured solutions for defense, space, intelligence, commercial, and civil applications, and our products are designed to perform in the harshest of environments. From human spaceflight and space exploration to missile defense, electronic warfare, and healthcare tech advancements, our talented team stays in lockstep with our customers to ensure the success of their missions. Do you want to help shape the future? In an environment where innovation and ideas go hand-in-hand? Then come join the Frontgrade Team! Why Work For Us We take care of our people and provide competitive health, wealth and wellbeing benefits – from day one. You’ll also discover learning and development opportunities so you can take your career to the next level – and beyond. Other benefits include: • Competitive Benefits: Medical (FSA + HSA), Dental, and Vision • Immediate 401K Vesting/Matching • Career Opportunity and Growth • Tuition Reimbursement • Student Loan Repayment • Generous PTO and 11 paid Holidays per year (8 regular and 3 floating) • 8 weeks of 100% Paid Family Leave • Profit Sharing Plan applies to all non-Annual Incentive Plan and non-Sales Incentive Plan employees. Overview The Mechanical Engineer II provides mechanical engineering expertise throughout the design process for electromechanical systems. Will also coordinate project design and analyze complex construction problems. Responsibilities KEY RESPONSIBILITIES • Develop comprehensive mechanical designs • Provide technical support to project teams as required from initial design to production • Perform intermediate-level analyses (thermal, structural, and tolerance) with some guidance of experienced engineers. Ansys and/or SolidWorks simulation experience preferred • Develop mechanical designs for electronics, fabrication fixturing, and test fixturing. SolidWorks Preferred • Create engineering documentation packages with working understanding of documentation control systems • Provide inputs to engineering design reviews including calculations, analyses, drawings, etc. to show compliance to specifications and project objectives and standards • Interact with customers and vendors as necessary based on project scope; makes presentations to communicate engineering findings Qualifications QUALIFICATIONS & EXPERIENCE • Minimum two (2) years of experience in a specialized functional discipline. • OR (6) years of experience may be considered in lieu of a Bachelors Degree. • Ability to obtain and/or maintain a Security Clearance. • Experience in the design of electronic or electromechanical products. • Aerospace Engineering (Bachelor's degree) or Mechanical Engineering (Bachelor's degree) or Related Field of Study • Applicable experience in lieu of a Degree may be considered. ADDITIONAL INFORMATION • This position requires access to technology, materials, software or hardware that is controlled by either ITAR or EAR U.S. export laws. As a condition to this job offer, in order to be employed in this position, you must be able to obtain an U.S. Government export license(s), as required by law. • Pay Range: $80,161.61 - $100,202.02 annually. Applicable pay within the posted range may vary based on factors including, but not limited to, geographical location, job function of the position, education, and experience of the successful candidate. WE ARE AN EQUAL OPPORTUNITY EMPLOYER We welcome differences and celebrate new ideas. We believe the diversity of our people inspires our creativity and drives our innovation. Everyone is welcome here, regardless of race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, protected veteran status, or genetic information. We are committed to working with and providing reasonable accommodations to individuals with disabilities. If you need a reasonable accommodation due to a disability for any part of the employment process, please email Careers@Frontgrade.com. If you have relevant skills that are not reflected in your resume, we welcome your application and encourage you to share more in an optional cover letter or to join our Talent Community Connect Portal - Connect (icims.com).
See More Details >>About us One team. Global challenges. Infinite opportunities. At Viasat, we’re on a mission to deliver connections with the capacity to change the world. For more than 35 years, Viasat has helped shape how consumers, businesses, governments and militaries around the globe communicate. We’re looking for people who think big, act fearlessly, and create an inclusive environment that drives positive impact to join our team. What you'll do Viasat is looking for a dynamic Senior Mechanical Design Engineer to join our growing team. In this exciting role, you will be responsible for the design, documentation and testing of electronics hardware. The day-to-day The day-to-day work encompasses electronics packaging, cabling, thermal analysis down to the component junction level, structural analysis, and qualification testing. You will ensure the design has the proper parts, materials and interface design so each module operates as intended within its environmental and performance requirements. You will work directly with a diverse staff including engineering, supply chain, manufacturing, and quality assurance to manage the product development. What you'll need • 12+ years of experience in Mechanical Design Engineering including electronics packaging. • Design experience creating 3D parts and assemblies using SolidWorks. • Experience creating and analyzing models in thermal analysis software (Ansys, Thermal Desktop, or similar). • Experience performing thermal analysis of electronics down to the junction level. • Experience in analyzing, developing, and selecting components of active thermal cooling solutions. • Experience working as part of a diverse team of multiple disciplines. • Ability to manage, allocate, and derive requirements, familiarity with MIL-STD-810 environmental requirements. • Ability to create specifications and presentations. • Proficiency in MS Word, Excel, and Power Point. • Strong communication skills – both verbal and written. • Bachelor's degree in Mechanical Engineering or a similar relevant engineering degree. • U.S. Citizenship Required. • Ability to obtain a U.S. Secret Clearance. • Up to 10% domestic travel. What will help you on the job • Cryptographic electronics packaging experience using SolidWorks. • Thermal analysis experience for electronic modules. • Active U.S. Secret Clearance. Salary range $127,000.00 - $201,000.00 / annually. For specific work locations within San Jose, the San Francisco Bay area and New York City metropolitan area, the base pay range for this role is $158,000.00- $237,000.00/ annually At Viasat, we consider many factors when it comes to compensation, including the scope of the position as well as your background and experience. Base pay may vary depending on job-related knowledge, skills, and experience. Additional cash or stock incentives may be provided as part of the compensation package, in addition to a range of medical, financial, and/or other benefits, dependent on the position offered. Learn more about Viasat’s comprehensive benefit offerings that are focused on your holistic health and wellness at https://careers.viasat.com/benefits. EEO Statement Viasat is proud to be an equal opportunity employer, seeking to create a welcoming and diverse environment. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity or expression, sexual orientation, national origin, ancestry, physical or mental disability, medical condition, marital status, genetics, age, or veteran status or any other applicable legally protected status or characteristic. If you would like to request an accommodation on the basis of disability for completing this on-line application, please click here.
See More Details >>Embarking on a career in the mechanical trade in Carlsbad, CA typically begins with an apprenticeship, combining hands-on experience with classroom learning, allowing individuals to earn while they learn. Apprenticeships last about three to four years, requiring many hours of training under licensed professionals. The U.S. Bureau of Labor Statistics reports 762,600 mechanical engineers nationwide, with a projected 11% job growth from 2023 to 2033. Apprentices in Carlsbad earn an average of $1,350 per week, with experienced professionals often exceeding $103,000 annually. Trade schools, unions, and platforms like Gild help aspiring mechanical trade professionals find apprenticeship opportunities, leading to a career with strong earning potential.
