The Electro-Mechanical Design Engineer collaborates with local and global engineering teams to develop high-voltage contactor products that meet demanding customer and system requirements. Responsibilities include the design and optimization of electro-mechanical components with a focus on switching performance, thermal behavior, and reliability. The role covers full product development from concept through validation and production launch, including prototype support, testing, and release of designs into production. The engineer ensures accurate and complete creation of drawings, specifications, and documentation, and manages timely release through internal systems while supporting cross-functional integration and manufacturing readiness.General Responsibilities • Leverages engineering fundamentals and organization to make sound decisions on complex technical issues • Detailed understanding of market and implications for business • Proactively challenge and drives the organization to deliver improved quality and performance related to engineering design • Product Strategy participant and driver • Maintain product documentation (drawings and specifications) • Direct interaction with customers to solicit product specifications requirements, schedule expectations and budget • Corrosion research and welding characterization &amp; has a strong understanding of mechanical engineering principles, materials, mechanics, fluid, thermo and heat transfer • Advanced knowledge of basic electrical circuits, microelectronic assembly, statistical methods, process control fundamentals and product test processes • Familiarity with manufacturing methods – welding, brazing, soldering, adhesive bonding, machining, stamping, molding, and forming. Basic knowledge of core manufacturing processes • Lead mechanical design activities while participating on cross-functional New Product Development (NPD) teams • Assist with design prototype builds and production validation activities in collaboration with manufacturing, quality, and supply • Familiarity with design, fabrication, modification, and evaluation in support of manufacturing operations such as machining, metal forming, plastics processing, welding and brazing, assembly, and material handlingExperience / Qualifications • A university degree required (i.e. Bachelors degree) or equivalent relevant work experience • Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands • Strong communication skills; oral, written and presentation • Strong organization, planning and time management skills to achieve results • Strong personal and professional ethical values and integrity • Holds self-accountable to achieving goals and standards • Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel) • Strong interpersonal &amp; collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers<h2>General Responsibilities</h2><ul><li>Apply strong engineering fundamentals to solve complex electro‑mechanical challenges in high‑voltage contactor design, including switching physics, arc behavior, and thermal management</li><li>Demonstrate deep understanding of HV DC systems, load characteristics, and their impact on contactor performance and reliability</li><li>Proactively challenge design assumptions and drive improvements in contact reliability, weld resistance, arc management, and lifecycle performance</li><li>Actively contribute to and drive product strategy for high-voltage switching devices and systems</li><li>Develop and maintain detailed product documentation (drawings, specifications, DFMEA, validation plans)</li><li>Interface directly with customers to define electrical, mechanical, and environmental requirements, including switching duty, fault conditions, and lifetime expectations</li><li>Lead contact system design and optimization, including:<ul><li>Contact materials and coatings</li><li>Contact force systems and kinematics</li><li>Weld resistance and de-sticking strategies</li></ul></li><li>Perform and support arc behavior characterization and suppression techniques, including blowout concepts, contact geometry, and magnetic field utilization</li><li>Conduct corrosion and environmental durability studies impacting long-term HV performance</li><li>Apply strong knowledge of:<ul><li>Electro‑mechanical systems and actuator design (solenoids, coils, dynamics)</li><li>Thermal behavior and heat transfer in HV switching components</li><li>Electrical conduction, contact resistance, and power loss mechanisms</li></ul></li><li>Utilize statistical methods and reliability analysis to evaluate contact wear, erosion, and failure modes</li><li>Lead mechanical design activities within cross-functional New Product Development (NPD) teams</li><li>Collaborate with electrical, manufacturing, and systems teams to ensure robust integration into HV architectures (e.g., EV, ESS, industrial DC)</li><li>Support prototype builds, validation testing, and root cause analysis for failures (e.g., weld events, contact erosion, coil performance)</li><li>Ensure designs are optimized for manufacturability, including processes such as:<ul><li>Precision stamping and forming (contact systems)</li><li>Welding and brazing (contact assemblies, terminals)</li><li>Coil winding and encapsulation</li></ul></li><li>Drive Design for Reliability (DfR) and Design for Manufacturing (DfM) practices specific to HV components</li></ul><h2>Experience / Qualifications</h2><ul><li>Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or related field (Master’s preferred)</li><li>Strong understanding of:<ul><li>High-voltage DC switching systems (typically 400–1000V+)</li><li>Contact physics, arcing phenomena, and weld mechanisms</li><li>Electro‑mechanical actuator systems and dynamic response</li></ul></li><li>Proven experience with:<ul><li>Contact materials (e.g., Cu, CuTe, AgSnO₂, AgNi) and their performance characteristics</li><li>Contact force design, tolerancing, and life optimization</li><li>HV insulation, creepage, clearance, and dielectric requirements</li></ul></li><li>Familiarity with HV safety standards and automotive/industrial requirements (e.g., IEC, UL, LV123/LV148 or similar)</li><li>Knowledge of arc mitigation techniques, precharge systems, and switching coordination strategies</li><li>Experience working with manufacturing processes relevant to contactor production:<ul><li>Welding, brazing, and joining technologies</li><li>Metal forming and precision machining</li><li>Assembly of electro‑mechanical systems</li></ul></li><li>Ability to analyze and interpret test data related to switching performance, endurance, and failure modes</li><li>Strong problem-solving skills with a focus on root cause analysis of field issues (e.g., contact welding, sticking, thermal overload)</li><li>Excellent communication skills and ability to work cross-functionally with customers, suppliers, and internal teams</li><li>Strong organizational and project management skills with the ability to manage multiple NPD activities in parallel</li><li>Proficient in Microsoft Office tools; experience with CAD and simulation tools is a plus</li></ul>#LI-EG1<h1>SmarterTogether</h1><ul><li>Collaborating at Sensata means working with some of the world’s most talented people in an enriching environment that is constantly pushing towards the next best thing</li><li>Employees work across functions, countries and cultures gaining new perspectives through mutual respect and open communication</li><li> As OneSensata, we are working together to make things work together </li></ul>Click here to view <a href="https://www.sensata.com/sensata-recruitment-privacy-policy">Sensata Recruitment Privacy Statement</a>Click here to view our <a href="https://www.sensata.com/sites/default/files/a/sensata_china_recruitment_privacy_policy.pdf">Sensata Recruitment Privacy Statement for China</a>NOTE:  If you are a current Sensata employee (or one of our Affiliates), please back out of this application and log into Workday via the Company Intranet to apply directly.  Type "FIND JOBS" in the Workday search bar.

Since 1963, Dynapower has provided power electronics solutions, along with an array of aftermarket services focused on continuous reliability and efficiency to an ever-expanding global customer base. We are a trusted leader in all types of power conversion equipment including high power rectifiers, inverters, DC/DC converters, integrated battery energy storage systems and transformers for use in hydrogen, e-mobility, energy storage, industrial, mining, defense and research applications. With headquarters and a 150,000 square-foot vertically integrated manufacturing facility in South Burlington, VT, Dynapower is collaborating with our partners and clients to shift the way our world uses power and advance our resilient, clean energy future.

Design Engineer with an Electro & Mechanical Focus

The Electro-Mechanical Design Engineer collaborates with local and global engineering teams to develop high-voltage contactor products that meet demanding customer and system requirements. Responsibilities include the design and optimization of electro-mechanical components with a focus on switching performance, thermal behavior, and reliability. The role covers full product development from concept through validation and production launch, including prototype support, testing, and release of designs into production. The engineer ensures accurate and complete creation of drawings, specifications, and documentation, and manages timely release through internal systems while supporting cross-functional integration and manufacturing readiness.General Responsibilities • Leverages engineering fundamentals and organization to make sound decisions on complex technical issues • Detailed understanding of market and implications for business • Proactively challenge and drives the organization to deliver improved quality and performance related to engineering design • Product Strategy participant and driver • Maintain product documentation (drawings and specifications) • Direct interaction with customers to solicit product specifications requirements, schedule expectations and budget • Corrosion research and welding characterization &amp; has a strong understanding of mechanical engineering principles, materials, mechanics, fluid, thermo and heat transfer • Advanced knowledge of basic electrical circuits, microelectronic assembly, statistical methods, process control fundamentals and product test processes • Familiarity with manufacturing methods – welding, brazing, soldering, adhesive bonding, machining, stamping, molding, and forming. Basic knowledge of core manufacturing processes • Lead mechanical design activities while participating on cross-functional New Product Development (NPD) teams • Assist with design prototype builds and production validation activities in collaboration with manufacturing, quality, and supply • Familiarity with design, fabrication, modification, and evaluation in support of manufacturing operations such as machining, metal forming, plastics processing, welding and brazing, assembly, and material handlingExperience / Qualifications • A university degree required (i.e. Bachelors degree) or equivalent relevant work experience • Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands • Strong communication skills; oral, written and presentation • Strong organization, planning and time management skills to achieve results • Strong personal and professional ethical values and integrity • Holds self-accountable to achieving goals and standards • Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel) • Strong interpersonal &amp; collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers<h2>General Responsibilities</h2><ul><li>Apply strong engineering fundamentals to solve complex electro‑mechanical challenges in high‑voltage contactor design, including switching physics, arc behavior, and thermal management</li><li>Demonstrate deep understanding of HV DC systems, load characteristics, and their impact on contactor performance and reliability</li><li>Proactively challenge design assumptions and drive improvements in contact reliability, weld resistance, arc management, and lifecycle performance</li><li>Actively contribute to and drive product strategy for high-voltage switching devices and systems</li><li>Develop and maintain detailed product documentation (drawings, specifications, DFMEA, validation plans)</li><li>Interface directly with customers to define electrical, mechanical, and environmental requirements, including switching duty, fault conditions, and lifetime expectations</li><li>Lead contact system design and optimization, including:<ul><li>Contact materials and coatings</li><li>Contact force systems and kinematics</li><li>Weld resistance and de-sticking strategies</li></ul></li><li>Perform and support arc behavior characterization and suppression techniques, including blowout concepts, contact geometry, and magnetic field utilization</li><li>Conduct corrosion and environmental durability studies impacting long-term HV performance</li><li>Apply strong knowledge of:<ul><li>Electro‑mechanical systems and actuator design (solenoids, coils, dynamics)</li><li>Thermal behavior and heat transfer in HV switching components</li><li>Electrical conduction, contact resistance, and power loss mechanisms</li></ul></li><li>Utilize statistical methods and reliability analysis to evaluate contact wear, erosion, and failure modes</li><li>Lead mechanical design activities within cross-functional New Product Development (NPD) teams</li><li>Collaborate with electrical, manufacturing, and systems teams to ensure robust integration into HV architectures (e.g., EV, ESS, industrial DC)</li><li>Support prototype builds, validation testing, and root cause analysis for failures (e.g., weld events, contact erosion, coil performance)</li><li>Ensure designs are optimized for manufacturability, including processes such as:<ul><li>Precision stamping and forming (contact systems)</li><li>Welding and brazing (contact assemblies, terminals)</li><li>Coil winding and encapsulation</li></ul></li><li>Drive Design for Reliability (DfR) and Design for Manufacturing (DfM) practices specific to HV components</li></ul><h2>Experience / Qualifications</h2><ul><li>Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or related field (Master’s preferred)</li><li>Strong understanding of:<ul><li>High-voltage DC switching systems (typically 400–1000V+)</li><li>Contact physics, arcing phenomena, and weld mechanisms</li><li>Electro‑mechanical actuator systems and dynamic response</li></ul></li><li>Proven experience with:<ul><li>Contact materials (e.g., Cu, CuTe, AgSnO₂, AgNi) and their performance characteristics</li><li>Contact force design, tolerancing, and life optimization</li><li>HV insulation, creepage, clearance, and dielectric requirements</li></ul></li><li>Familiarity with HV safety standards and automotive/industrial requirements (e.g., IEC, UL, LV123/LV148 or similar)</li><li>Knowledge of arc mitigation techniques, precharge systems, and switching coordination strategies</li><li>Experience working with manufacturing processes relevant to contactor production:<ul><li>Welding, brazing, and joining technologies</li><li>Metal forming and precision machining</li><li>Assembly of electro‑mechanical systems</li></ul></li><li>Ability to analyze and interpret test data related to switching performance, endurance, and failure modes</li><li>Strong problem-solving skills with a focus on root cause analysis of field issues (e.g., contact welding, sticking, thermal overload)</li><li>Excellent communication skills and ability to work cross-functionally with customers, suppliers, and internal teams</li><li>Strong organizational and project management skills with the ability to manage multiple NPD activities in parallel</li><li>Proficient in Microsoft Office tools; experience with CAD and simulation tools is a plus</li></ul>#LI-EG1<h1>SmarterTogether</h1><ul><li>Collaborating at Sensata means working with some of the world’s most talented people in an enriching environment that is constantly pushing towards the next best thing</li><li>Employees work across functions, countries and cultures gaining new perspectives through mutual respect and open communication</li><li> As OneSensata, we are working together to make things work together </li></ul>Click here to view <a href="https://www.sensata.com/sensata-recruitment-privacy-policy">Sensata Recruitment Privacy Statement</a>Click here to view our <a href="https://www.sensata.com/sites/default/files/a/sensata_china_recruitment_privacy_policy.pdf">Sensata Recruitment Privacy Statement for China</a>NOTE:  If you are a current Sensata employee (or one of our Affiliates), please back out of this application and log into Workday via the Company Intranet to apply directly.  Type "FIND JOBS" in the Workday search bar.

Design Engineer with an Electro & Mechanical Focus

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Dynapower

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