Mechanical Engineer, Staff to Principal level

Enphase Energy is a global energy technology company and a leading provider of solar, battery, and electric vehicle charging products. Founded in 2006, our innovative microinverter technology revolutionized solar power, making it a safer, more reliable, and scalable energy source. Today, the Enphase Energy System enables users to make, use, save, and sell their own power. Enphase is also one of the most successful and innovative clean energy companies in the world, with more than 80 million products shipped across 160 countries.

Join our dynamic teams designing and developing next-gen energy technologies and help drive a sustainable future!

About the role

The Enphase Power Systems Innovation team in the CTO's office is responsible for defining, prototyping, and supporting Enphase's Solid State Transformer products. The team is an integrated, multi-disciplinary group looking for motivated individuals who can contribute and collaborate closely with the team to deliver innovative solutions. As a team member, you will solve some of the most exciting problems in the energy space and help shape the direction of our products. We are looking for a Mechanical Design Engineer with a strong background in the mechanical design and integration of electrical equipment — including busbars, wire harnesses, electronic board packaging, and connectors — who will own the integration of the support and control system for Enphase's first-generation Solid State Transformer product.

What You Will Do

Design high-current busbar assemblies — including conductor sizing, layout routing, thermal management, and mechanical mounting

Own wire harness design and routing, including connector selection, terminal specification, cable management, strain relief, and harness drawing packages

Design electronic board packaging solutions — including enclosures, mounting hardware, EMI shielding, thermal interface management, and serviceability provisions

Specify and design electrical connectors and interconnect systems, ensuring reliable mating, adequate current ratings, and compatibility with assembly and service workflows

Perform electrical insulation coordination for internal mechanical components, including creepage and clearance analysis, material selection for dielectric performance, and compliance with relevant voltage class requirements

Ensure field-replaceable boards are accessible and documented with clear service procedures

Ensure the design is manufacturable— selecting appropriate fabrication methods, tolerancing for producibility, and collaborating with contract manufacturing partners to ensure smooth production ramp

Perform structural and thermal analysis (hand calculations and FEA/CFD) on busbars, mounting structures, and packaging assemblies to validate performance under rated and fault conditions

Produce 2D drawings and 3D CAD models, evaluate parts, and collaborate with internal stakeholders, suppliers, and contract manufacturing partners to bring your design to market

Specify key functional and performance requirements; design and execute verification test plans

Complete documentation for design, testing, and analysis

Hands-on fabrication of electromechanical assemblies and prototypes

Mentor junior staff

Who You Are and What You Bring

Job title and level determined by candidate experience:

Staff Engineer: BS + 8 yrs | MS + 6 yrs | PhD + 3 yrs: Sr. Staff Engineer: BS + 12 yrs | MS + 8 yrs | PhD + 5 yrs: Principal Engineer: BS + 15 yrs | MS + 12 yrs | PhD + 8 yrs

Candidates with greater experience are strongly encouraged to apply

Ability to solve problems independently and work effectively on early-stage product development efforts with ambiguous requirements and tasks

Ability to take ownership of development tasks and manage various high-importance tasks simultaneously

Significant experience in the mechanical design and integration of electrical support equipment for power electronics, power conversion, or analogous high-power electrical products

Strong proficiency in busbar design — conductor sizing, laminated busbar stack-ups, insulation systems, thermal rise calculations, and mechanical mounting methods

Demonstrated experience in wire harness design — routing, connector and terminal selection, wire gauge specification, and harness drawing creation

Experience designing mechanical packaging for electronic boards, including thermal management, shock and vibration isolation, EMI considerations, and board-level interconnects

Expertise in electrical insulation coordination — creepage and clearance analysis per IEC 60664-1 or equivalent, selection of insulating materials, and design practices for medium-voltage (>1 kV) environments

Strong understanding of connector systems for power and signal applications — contact ratings, environmental sealing, keying, and mating cycle durability

Demonstrated ability to design for manufacturing — tolerance analysis, process selection (sheet metal fabrication, CNC machining, injection molding, stam…