Mechanical Systems Engineer – Power Conversion & Distribution Systems

Career Area:

Job Description:

Your Work Shapes the World at Caterpillar Inc.

When you join Caterpillar, you're joining a global team who cares not just about the work we do – but also about each other.  We are the makers, problem solvers, and future world builders who are creating stronger, more sustainable communities. We don't just talk about progress and innovation here – we make it happen, with our customers, where we work and live. Together, we are building a better world, so we can all enjoy living in it.

We are looking for an experienced Mechanical Systems Engineer to lead the design, development, and integration of mechanical systems for Power Conversion & Distribution systems in electrified platforms.

This role focuses on system architecture, enclosure design, thermal-mechanical integration, and mechanical component design (DFM/DFA) with a strong emphasis on compact, lightweight, and high power-density design philosophy.

You will work closely with electrical, thermal, and manufacturing teams to deliver robust, manufacturable, and optimized mechanical solutions for demanding environments such as automotive and industrial applications.

Key Responsibilities

• Define mechanical system architecture for power conversion and distribution systems, translating requirements into subsystem and component-level designs
• Lead design and development of enclosures, housings, and structural components for power electronic systems (inverters, converters, Battery Power distribution units)
• Drive compact and lightweight design strategies, optimizing packaging for space, weight, thermal performance, and structural integrity
• Own mechanical design for manufacturability and assembly (DFM/DFA), ensuring cost-effective and scalable production
• Perform material selection (metals, polymers, composites) considering thermal, mechanical, environmental, and cost constraints
• Ensure robust sealing, ingress protection (IP ratings), and environmental durability for harsh operating conditions
• Collaborate with electrical and PCB teams for mechanical-electrical integration, ensuring proper clearances, mounting, and cable routing
• Conduct and guide FEA analysis (structural, thermal, vibration) to validate design robustness and reliability
• Support prototype builds, testing, and validation, including root cause analysis and design improvements

Technical Skills

• Mechanical system architecture and product integration
• Enclosure and housing design for power electronics
• Compact packaging and lightweight design optimization
• DFM/DFA principles for high-volume manufacturing
• Thermal management (heat sinks, cooling strategies, interface materials)
• Material science (aluminum, plastics, coatings, composites)
• Structural and vibration design for harsh environments
• Sealing, gasketing, and IP-rated enclosure design
• Tolerance stack-up and GD&T
• Cross-domain integration (mechanical + electrical systems)

Tools and Software

• CAD: Creo, SolidWorks, CATIA, NX
• Simulation: ANSYS, Abaqus (structural & thermal FEA – Good to have)
• Thermal Analysis Tools: Icepak, Flotherm (Good to have)
• PLM Tools: Windchill, Teamcenter

Soft Skills and Teamwork

• Strong system-level thinking with attention to detail
• Ability to work collaboratively across electrical, thermal, and manufacturing domains
• Effective communication and design review capability
• Problem-solving mindset with focus on practical, manufacturable solutions
• Ownership from concept through production

Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering with 8 to 15 years of experience
• Experience in power electronics, electrification, automotive, or industrial systems preferred
• Proven experience in compact, lightweight enclosure design for high-power systems

Additional information: This job required 5days working from office.

Posting Dates:

Caterpillar is an Equal Opportunity Employer.  Qualified applicants of any age are encouraged to apply

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