Job Title: Senior Mechanical Engineer - Power Systems and Electronics Packaging
Job Description
This role focuses on the mechanical design, packaging, and validation of advanced power electronics and energy storage systems for demanding land-based, shipboard, airborne, and subsea environments. The Senior Mechanical Engineer will lead the 3D packaging of complex power converters and PLC systems, design thermal management solutions, perform structural and thermal analyses, and support hardware build, test, and rapid prototyping efforts. The position offers the opportunity to work on cutting-edge wide band gap Gallium Nitride (GaN) and Silicon Carbide (SiC) power electronics within a highly collaborative engineering and manufacturing environment.
Responsibilities
Package complex power converters, energy storage systems, and PLC systems using 3D mechanical design tools.
Build and test complex power converters, energy storage systems, and PLC systems in collaboration with the operations and test teams.
Design thermal management systems for power electronics, including cold plates, heat exchangers, and overall thermal management systems for large power electronics.
Perform structural analysis for components, support structures, and ruggedized enclosures subjected to harsh environmental conditions, including shock and vibration.
Use FEA, CFD, and hand calculations to perform detailed thermal and structural analyses.
Create, review, and release proto@type and production-level mechanical 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 documentation and build documentation in conjunction with the operations team to support manufacturing and assembly.
Write and review mechanical engineering-focused patents, white papers, and technical conference or journal articles.
Mentor junior engineers by providing technical guidance, design review feedback, and support in analysis and testing 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 content for new opportunities.
Contribute to MW-scale power converter projects 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.
Support the design of naval shipboard and undersea submersible components, ensuring robust performance in demanding environments.
Essential Skills
Bachelor's degree in mechanical engineering.
Experience in mechanical design and 3D modeling for complex electromechanical systems.
Proficiency with CAD tools for 3D mechanical design, such as SolidWorks, Creo, Pro/ENGINEER (Pro-E), or similar.
Hands-on experience with mechanical engineering design for power systems, power electronics, or machine design applications.
Ability to design thermal management systems for power electronics, including cold plates, heat exchangers, and high-performance thermal solutions.
Experience performing structural analysis for components, support structures, and ruggedized enclosures under harsh environmental conditions, including shock and vibration.
Proficiency in using FEA and CFD tools for thermal and structural analysis, as well as performing supporting hand calculations.
Ability to create, review, and release production-quality mechanical drawings in accordance with GD&T standards.
Experience with manufacturing-oriented mechanical design and working with on-site manufacturing in a rapid prototyping environment.
Strong analytical skills in thermal analysis and mechanical analysis, including use of tools such as ANSYS and Altair.
Ability to obtain a U.S. Department of Defense security clearance.
United States citizenship, as required by applicable ITAR program restrictions.
Additional Skills & Qualifications
Graduate-level coursework or advanced degree in mechanical engineering, which may substitute for some work experience.
Proficiency with CREO 3D modeling software for mechanical design and packaging.
Experience with Windchill PLM software; administrator-level experience is a plus.
Experience with FEA and CFD modeling software packages for detailed thermal and structural simulations.
Background in designing high-performance heat exchangers and advanced thermal management systems.
Experience in mechanical shock and vibration analysis for ruggedized systems.
Familiarity with SimLab, Creo Simulate, and Creo Flow for structural, thermal, and fluid simulations.
Experience preparing technical data packages and comprehensive design documentation for complex systems.
Exposure to power electronics, energy storage systems, motor drives, and related power systems applications.
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 machine learning or AI-based controls as applied to power systems and thermal management.
Experience writing or contributing to patents, white papers, and technical conference or journal publications.
Demonstrated ability to mentor junior engineers and lead cross-functional engineering teams.
Work Environment
The role is based in a growing power systems facility that recently expanded from a 12,000 square foot site to a new 40,000 square foot location in Baltimore, Maryland. The team consists of approximately 40-45 employees and focuses on designing and manufacturing large power systems, wide band gap (GaN/SiC) power converters and components, and gate drivers for advanced naval shipboard applications. The main programs include megawatt-scale power supplies such as the Mission System Bus Node (MSBN). The environment combines office-based design work with hands-on lab and manufacturing floor activities, supporting rapid prototyping, hardware build, and test in a 1.0 MW AC/DC low- and medium-voltage test facility. Engineers work closely with on-site manufacturing, leveraging advanced tools for power electronics, energy storage, motor drives, real-time modeling, controller hardware-in-the-loop (CHIL), power hardware-in-the-loop (PHIL), digital twin modeling, thermal analysis and design, and machine learning or AI-based controls. The culture emphasizes collaboration, technical excellence, and innovation in delivering robust solutions for land-based, shipboard, airborne, and subsea applications.
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 Jun 5, 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.
