Staff Mechanical Engineer

Smart Wires provides advanced power flow control solutions and analytics that enable controllable power systems. This gives grid operators more control over where power flows and helps them use their existing networks more effectively. Our solutions support system reliability, reduce congestion, and make it easier to integrate new load and generation while minimizing costs and community disruption. We collaborate with customers to achieve their strategic objectives and help them face an uncertain energy future with flexible, high-impact solutions.

Position Summary

The Staff Mechanical Engineer will play a critical role in the design, development, analysis, validation, and RCA of complex mechanical and electro-mechanical systems. You will contribute as a hands-on technical expert while providing technical leadership across projects, working through all phases of product development from conceptualization to production within a fast-paced, collaborative environment.

The role requires a detail-oriented individual with deep expertise in finite element analysis and thermal modelling, who is also highly motivated and self-directed. The individual will assume an important role in commercialization of the new products by leading and supporting simulations, DfX, procurements, in-process testing, manufacturing, and EoL activities.

Primary Responsibilities

• Collaborate cross-functionally with the Engineering, Manufacturing, Projects & Services, and Product Development Management teams to deliver robust design solutions while supporting prototype builds, analysis, testing, and field remedial activities.
• Support design solutions through all phases of development, from conceptual design to manufacturing release.
• Manage and support the production of engineering documents including part and assembly drawings, manufacturing instructions, and bill of material.
• Establish and support subsystem test strategies for RCA and simulation/verification/validation.
• Design components, assemblies, and tooling in support of NPI.
• Analyze and solve technical problems, and provide solutions that can be implemented in a timely manner.
• Support simulation efforts using ANSYS, ANSYS Fluent, or equivalent tools for FEA and thermal modeling, including static, dynamic, thermal, linear, and non-linear analyses on assemblies ranging from few to 800+ parts.
• Support dynamic and vibration analyses, including modal analysis, modal testing, and analysis of dynamically induced vibration for multi-body systems.
• Provide hands-on troubleshooting and engineering support within a rapid development cycle.
• Apply GD&T and tolerance analysis in mechanical design and documentation.

Requirements

Required skills and experience

• Bachelor’s or Master’s degree in Mechanical Engineering or a related field.
• 15+ years of engineering work experience.
• Strong leadership, communication, and problem-solving skills.
• Strong proficiency in using SolidWorks, SolidWorks PDM Vault, and SolidWorks Simulation Package to create design concepts, manage and generate detailed drawings and assemblies, analyze parts, and material.
• Demonstrated ability to create accurate timelines and resource allocations for running medium to large scale programs.
• Competent in using Agile PLM to manage BoM, ECO, MCO, CARs, work instructions, in-process testing, and reports.
• In-depth knowledge of engineering materials especially aluminum, copper, polymers, and composites for fatigue, wear, impact, temperature extremes, dielectric insulation for high and medium voltages, coating for electrical insulators & conductors, corrosion, and aging due to long term exposure to weather.
• Experience in manufacturing processes such as welding, machining, sheet metal, casting, injection molding, and 3D printing per DFX best practices.
• Knowledge of ASME Y14.5-2009 Dimensioning and Tolerancing (GD&T) standards and practices.
• Experience in test fixture design, procurement and fabrication.
• Excellent written and verbal communication and presentation skills.
• Demonstrated success working in a collaborative team environment while mentoring and supporting peers.

Desired skills and experience

• PhD in mechanical engineering or related fields.
• Prior design and manufacturing experience at the Senior level working on FACTS devices, electro-mechanical systems, and large outdoor electrical enclosures.
• Knowledge regarding power electronics.
• Ability to recommend equipment purchases and manage consumables specifications.
• Experience in leveraging AI to improve performance of day-to-day tasks.
• Experience working within ISO regulated environments.

Location

This role is located at the Smart Wires HQ in Durham, NC

Benefits

At Smart Wires, we strive to foster an inclusive and supportive environment that focuses on our employees’ total wellbeing, and our benefit offerings reflect that commitment to our people.

We offer:

• Unlimited annual leave
• Paid volunteer time off to give back to your community.
• Eighteen weeks of paid parental leave to support you and your family.
• Competitive total compensation packages that include, salary, bonus and equity.
• A comprehensive benefits package, including medical, dental, and vision insurance, life and disability coverage, a 401(k) retirement plan with company match, and more.

The Culture

We are passionate about creating a culture that empowers our team to create positive change for everyone and achieve their full potential, based on our core values:

Making an impact - We are passionate and ambitious about a better future for everyone. We are laser-focused on creating a meaningful, positive impact with real change for our customers, our industry, electricity consumers, and the planet.

Collaboration to drive success - We collaborate with each other, and our stakeholders, because we know even better outcomes come from great teamwork. We have humility because we know even better outcomes come from great teamwork. We have humility which allows us to listen, learn and improve. We value diverse perspectives and seek high impact results.

Accountability - We take responsibility for our actions and behaviors, and for the outcomes we deliver. Acting with integrity and authenticity – and maintaining clear, open communication – ensures we are always improving, and delivering safe, high-quality solutions. We do what we say we will do.

Tenacious courage - We are clear on our path. We have always pioneered new ideas that challenge the status quo, even when it’s not popular. We have tenacity, grit and determination. We push the boundaries of what’s thought to be possible – so we can leave the world a better place than we found it.

**Smart Wires is committed to diversity in our organization and building an equitable and inclusive environment for people of all backgrounds and experiences. We provide equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability or genetics. Smart Wires complies with applicable federal, state and local laws governing nondiscrimination and we especially encourage members of traditionally underrepresented communities to apply, including women, people of any skin color, LGBTQ people, veterans, and people with disabilities.**