Mechanical Engineer

Job Title:

SR Mechanical Engineer - Power Systems & 3D Electronics Packaging Job Description This role focuses on the mechanical design, packaging, and validation of advanced power electronics and energy storage systems used in demanding environments such as land-based, shipboard, airborne, and subsea applications. The Senior Mechanical Engineer will lead the design of 3D electronics packaging, thermal management systems, and ruggedized structures, while also supporting hardware build and test activities. This position offers the opportunity to contribute to cutting-edge wide band gap power electronics, collaborate with cross-functional teams, and mentor junior engineers in a rapidly growing power systems organization. Responsibilities Package complex power converters, energy storage systems, and PLC systems, ensuring robust mechanical integration and serviceability. Build and test complex power converters, energy storage systems, and PLC systems in collaboration with electrical and manufacturing teams. Design thermal management systems for power electronics, including cold plates, heat exchangers, and overall thermal management systems for large power electronics platforms. Perform structural analysis for components, support structures, and ruggedized enclosures operating in harsh environmental conditions, including shock and vibration. Use FEA, CFD, and hand calculations to perform detailed thermal and structural analyses that guide design decisions. Create, review, and issue prototype and production-level drawings in accordance with GD&T standards. Source vendors and communicate with suppliers to obtain quotes and support procurement of custom mechanical parts. Prepare and deliver technical presentations and design reviews for customers and internal stakeholders. Create and maintain process and build documentation in conjunction with the operations team to support repeatable manufacturing and assembly. Write and review mechanical engineering-focused patents, whitepapers, and technical conference or journal articles to capture and share technical innovations. Mentor junior engineers by providing technical guidance, design reviews, and support in day-to-day engineering activities. Lead cross-functional teams to develop solid-state power conversion systems from concept through production. Provide technical input into business development activities, including proposal support and technical strategy. Support immediate projects such as megawatt-scale power converters for naval ship applications, including preparation of technical data packages and related documentation. Perform structural, thermal, and shock and vibration analyses using tools such as SimLab, Creo Simulate, and Creo Flow. Contribute to naval shipboard and undersea submersible component design, ensuring compliance with performance and environmental requirements. Work closely with on-site manufacturing in a rapid prototyping environment to validate designs and support continuous improvement. Essential Skills Bachelor's degree in mechanical engineering (graduate work is acceptable in lieu of some work experience). Experience in mechanical design and mechanical engineering for complex power systems or related equipment. Proficiency in 3D CAD modeling for mechanical design, using tools such as SolidWorks, Creo, Pro/Engineer (Pro-E), or equivalent. Hands-on experience with packaging of power electronics, energy storage systems, and PLC systems. Demonstrated ability to design thermal management systems for power electronics, including cold plates and high-performance heat exchangers. Experience performing structural analysis for components, support structures, and ruggedized enclosures subjected to harsh environmental conditions and shock and vibration. Proficiency with FEA and CFD modeling software packages for thermal and structural analysis. Ability to perform hand calculations to validate and supplement simulation results. Experience creating, reviewing, and releasing mechanical drawings in accordance with GD&T standards. Familiarity with manufacturing processes and machine design within a power or industrial systems context. Strong engineering analysis skills, including thermal analysis and mechanical shock and vibration analysis. Ability to lead cross-functional teams and mentor junior engineers. Strong written and verbal communication skills for technical presentations, design reviews, and documentation. Additional Skills & Qualifications Experience with CREO 3D modeling software. Experience with Windchill PLM software; administrator experience is a plus. Experience with SimLab, Creo Simulate, and Creo Flow for structural, thermal, and flow analyses. Familiarity with ANSYS and Altair tools for analysis. Experience working with on-site manufacturing in a rapid prototyping environment. Expereince in designing thermal management systems and high-performance heat exchangers. Experience with mechanical shock and vibration analysis for naval, aerospace, or similarly demanding applications. Exposure to power electronics, energy storage, motor drives, and related power systems. Familiarity with real-time modeling, controller hardware-in-the-loop (CHIL), power hardware-in-the-loop (PHIL), and digital twin modeling environments. Interest or experience in thermal analysis and design, machine learning or AI-based controls, and rapid prototyping. Experience preparing technical data packages and related documentation for complex systems. Experience contributing to patents, whitepapers, and technical conference or journal publications. Job Type & Location This is a Contract to Hire position based out of Halethorpe, MD. Pay and Benefits The pay range for this position is $45.00 - $70.00/hr. Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:

• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan - Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave) Workplace Type This is a fully onsite position in Halethorpe,MD.

Application Deadline This position is anticipated to close on May 29, 2026. About Actalent Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law. If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance:

Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector:

It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability. Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.