Mechanical Engineer_High Voltage_TN_202609_034

Responsible of mechanical design for an integrated x-in-1, 800+ V high-voltage control module for NEVs, ensuring robust packaging, thermal/structural performance, HV safety, EMC-ready interfaces, sealing/IP integrity, and manufacturability from concept through SOP and across derivatives.

1.3 Direct space-claim, vehicle-level packaging studies, and bracket/mounting interfaces in compliance with commercial vehicle chassis installation zones.

About Aumovio

• Ready to take your career to the next level? The future of mobility isn’t just anyone’s job. ​Make it yours! ​Join AUMOVIO. Own What’s Next.​
• Since its spin-off in September 2025 AUMOVIO continues the business of the former Continental group sector Automotive as an independent company.
• The technology and electronics company offers a wide-ranging portfolio that makes mobility safe, exciting, connected, and autonomous.
• This includes sensor solutions, displays, braking and comfort systems as well as comprehensive expertise in software, architecture platforms, and assistance systems for software-defined vehicles.
• In the fiscal year 2024 the business areas, which now belong to AUMOVIO, generated sales of 19.6 billion Euro.
• The company is headquartered in Frankfurt, Germany and has about 87.000 employees in more than 100 locations worldwide.

Responsibilities

• 1 Architectural Definition & Concept Development 1.1 Break down OEM customer technical specifications into mechanical requirements, boundary envelopes, and Interface Control Documents.
• 1.2 Lead the concept trade-off studies and mechanical architecture of high-voltage "X-in-1" units, integrating housing, cover, busbars, power modules (SiC/IGBT), control boards, thermal cooling circuits, and high-voltage interconnects.
• 2 Detailed Mechanical Design & DFx Execution 2.1 Design structural aluminum die-cast housings, extruded cooling plates, stamped/bent copper and aluminum busbars, injection-molded parts, and EMI shielding covers using 3D CAD software.
• 2.2 Apply Design for Manufacturing, Assembly, and Testing (DFM/DFA/DFT) rules to optimize production yields, cycle times, and scrap rates across casting, CNC machining, automated dispensing, and screw-driving processes.
• 2.3 Perform detailed tolerance stack-up analyses (1D/3D worst-case and RSS statistical evaluations) and create 2D manufacturing drawings following GD&T standards 3 Thermal Management & Structural Integrity Optimization 3.1 Coordinate closely with simulation specialists on CFD (pressure drop, flow distribution, cooling efficiency) and FEA (vibration, shock, screw prestress) analyses.
• 3.2 Ensure structural designs withstand vehicle environments (severe shock, sustained multi-axis random vibration per ISO 16750-3).
• 3.3 Select and integrate Thermal Interface Materials (TIM)—including structural gap fillers, thermal pads, and adhesives—to safeguard low thermal resistance across all operating conditions.
• 4 High-Voltage Safety, Sealing & Reliability Assurance 4.1 Ensure mechanical compliance with automotive HV safety directives (ISO 6469, GB/T 18384, ECE R100), securing mandatory creepage and clearance distances, touch protection (IPXXB/IPXXD), and HVIL integration.
• 4.2 Engineer sealing concepts (elastomer gaskets, Formed-In-Place Gaskets / FIPG) and pressure equalization membranes (protective vents) to achieve IP67 and IP6K9K ingress protection ratings over vehicle service life.
• 4.3 Lead Design FMEA (DFMEA) according to AIAG-VDA standards to identify and mitigate mechanical failure modes early.
• 5 Industrialization, Supplier Technical Management & Problem Solving 5.1 Guide mechanical suppliers (die-casters, mold makers, stamping houses, connector manufacturers) through technical feasibility reviews, tooling trials, and PPAP approval 5.2 Support internal prototype builds (A/B/C samples), resolve assembly problems, drive

Engineering Change Requests (ECR), and implement

• Root Cause Analysis (8D, Ishikawa, 5-Why).
• 5.3 Act as the technical lead for production lines during line setup, clamping/screwing process qualifications, and end-of-line (EOL) air-leak testing.
• 6 Risk, quality, and compliance management 6.1 Lead mechanical risk identification and mitigation (DFMEA ownership/oversight, risk list, contingency planning).
• 6.2 Ensure compliance to applicable standards and customer specs 6.3 Plan and track DVP for mechanical/environmental, thermal, vibration, leak/IP, and durability; ensure test readiness, issue closure (8D), and change implementation via ECNs.
• 6.4 Coordinate APQP/PPAP for mechanical parts and assemblies; oversee PFMEA/control plans with suppliers and plant.
• Cost, weight, and value engineering Set and track cost/weight targets for mechanical content; lead VA/VE workshops (e.g., casting consolidation, fastener strategy, surface treatments, TIM optimization) without compromising reliability.
• 8.
• Communication and stakeholder management 8.1 Provide clear status, risk, and decision logs to leadership and customers; prepare gateway packages and lead design/quality reviews.
• 8.2 Manage issue/action registers, KPIs dashboards, and lessons learned; deploy standards and best practices across programs.

Requirements

• Bachelor’s or Master’s degree in Mechanical Engineering, Mechatronics, Automotive Engineering, or equivalent.
• 5+ years in mechanical development for automotive high voltage control modules 3) Demonstrated delivery of enclosure/cooling/sealing-heavy products under automotive quality systems (APQP, PPAP, IATF 16949).
• Working knowledge of 800V-1000V + HV safety and mechanical topics (creepage/clearance, CTI-driven materials, UL94 flammability).
• Background in die casting and welded aluminum housings, sealing systems (O‑rings, form-in-place gaskets, venting), and thermal interface materials/potting.
• Launch experience for integrated multi-function HV modules (e.g., OBC + DC/DC + PDU/inverter controls) with tight packaging and thermal zoning.
• Familiarity with EMC from a mechanical perspective (shielding joints, grounding continuity).
• Proficiency with CAD/PLM-driven release processes.
• Creo @ Windchill and change control (ECR/ECN).
• Strong cross-functional collabration, supplier management, and communication skills.
• Fluent English communication