Senior Staff Mechanical Engineer - Inverter, BESS

Job description

Enphase Energy is a global energy technology company and leading provider of solar, battery, and electric vehicle charging products. Founded in 2006, Enphase transformed the solar industry with our revolutionary microinverter technology, which turns sunlight into a safe, reliable, resilient, and scalable source of energy to power our lives. Today, the Enphase Energy System helps people make, use, save, and sell their own power. Enphase is also one of the fastest growing and innovative clean energy companies in the world, with approximately 80 million products installed across more than 160 countries. We are building teams that are designing, developing, and manufacturing next-generation energy technologies and our work environment is fast-paced, fun and full of exciting new projects. Must be available to work on-site at our Bangalore office 5 days per week. About the role: As a Senior Staff Mechanical Engineer - Inverter, BESS, you will own and drive mechanical and structural design of the inverter variant alongside other hardware and mechanical engineers for MW/MWh-scale utility Battery Energy Storage Systems (BESS) serving data centers, spanning outdoor cabinets and containerized platforms. This role requires deep, hands-on expertise in structural design, electro-mechanical product development for outdoor applications, FEM/FEA analysis, and product validation. You will work closely with thermal, electrical hardware, sourcing, manufacturing, and quality teams to ensure the product meets performance, reliability, manufacturability, serviceability, compliance, and cost targets — delivering production-ready designs from concept through deployment. What will you do: Own structural design from concept to final product. Develop electro-mechanical products for outdoor applications that meet various Ingress Protection (IP) ratings. Perform product structural analysis across injection molded plastics, aluminum metal extrusions, and other materials. Develop structural solutions for components such as PCBs and heatsinks, including warpage and stress analysis under various load conditions. Design custom bulkhead connectors for high-voltage DC (800–1000V) and high-voltage AC (600V) applications. Design new components and products — sometimes as a sole contributor, often as part of a team. Review and analyze solutions to achieve the best outcome for performance, cost, and schedule. Support sourcing, manufacturing, and quality teams with mechanical expertise. Prepare and execute test plans for structural validation (vibration, drop test, impact test, thermal test, thermal cycling, damp heat humidity test, and others). Conduct failure analysis and root-cause identification. Generate and review documentation, including concept proposals, analysis reports, component specifications, and review minutes. Review and approve components, including global travel to vendor sites during the pre-production stage. Provide technical leadership, and mentor and grow other junior engineers under this role. Who You Are and What You Will Bring: Bachelor’s degree in mechanical engineering with 12+ years of relevant industry experience, or a Master's degree (Product Design, Mechanical Design, Thermal Engineering, or a related discipline) with 8+ years of relevant industry experience. Strong fundamentals in engineering mechanics and strength of materials. Strong fundamentals in FEM/FEA (structural and thermal) analysis — a key requirement. Strong execution of inverter thermals using Flotherm, Ansys Icepak, or SolidWorks tools. In-depth knowledge of design for manufacture for parts made through injection molding, sheet metal, stamping, and milling/turning. Proficiency with CAD tools (SolidWorks or equivalent) and EPDM. Sound knowledge of inverter standards such as UL1741, IEC 62109, and NEMA, as well as country-specific standards. Thorough knowledge of product validation methods (vibration, drop test, impact test, connector reliability, and others). Clear written and verbal communication, including strong presentation skills. Experience in design and sustaining activities on high-volume products (500k+ to 1 million per annum). Rapid prototyping with 3D printing or high-temperature resin materials. Previous experience in the high-power or consumer products industries.