Sr Staff Engineer, Mechanical
Description
Enphase Energy is a global energy technology company and leading provider of solar, battery, and electric vehicle charging products. Founded in 2006, Enphase transformed the solar industry with our revolutionary microinverter technology, which turns sunlight into a safe, reliable, resilient, and scalable source of energy to power our lives. Today, the Enphase Energy System helps people make, use, save, and sell their own power. Enphase is also one of the fastest growing and innovative clean energy companies in the world, with approximately 80 million products installed across more than 160 countries.
We are building teams that are designing, developing, and manufacturing next-generation energy technologies and our work environment is fast-paced, fun and full of exciting new projects.
If you are passionate about advancing a more sustainable future, this is the perfect time to join Enphase!
Must be available to work on-site at our Bangalore office 5 days per week.
About the role:
As a Senior Staff Mechanical Engineer, you will be responsible for the endtoend mechanical architecture, detailed design, and system integration of commercial and utilityscale Battery Energy Storage Systems (BESS). This includes cabinets, racks, and containerized platforms using sheetmetal and welded structures, cast and machined components, polymers and elastomers for insulation and sealing, and durable coatings and finishes for longterm outdoor operation.
You will integrate mechanical systems with battery modules, highpower electrical assemblies (PCBs, contactors, protection devices), busbars, and cable harnesses, ensuring safe electrical clearances, thermal performance, manufacturability, and serviceability. You will also integrate forcedair, HVAC, and liquidcooling solutions, working closely with electrical, compliance, and manufacturing teams. Through structured problemsolving across new product development and field issues, you will drive improvements in reliability, safety, serviceability, and cost.
What you will do:
Ability to work independently and lead mechanical design projects or guide small teams, while delivering on schedule, cost, quality, and performance targets.
Extensive experience executing 3D and 2D CAD (SolidWorks, EPDM), maintaining releaseready design documentation, and leading mechanical and crossfunctional design reviews. Strong understanding of structural and thermal design for heavyduty outdoor cabinets and containerized systems, including fans, HVAC, and liquidcooling solutions, and effective ECAD/MCAD integration. Demonstrated experience planning and executing prototype builds, proofofconcepts, and Design Verification Testing (DVT), including rapid design iteration. Capability to define and execute comprehensive mechanical test plans (inhouse and external labs) covering static/dynamic loads, fatigue, environmental exposure, UL/IEC certification, and reliability requirements.
Who you are and what you bring:
12+ years (BE/BS) or 8+ years (Master’s) of handson experience in mechanical product design, development, and testing, with mandatory experience designing Commercial and Utilityscale Battery Energy Storage Systems (BESS).
Bachelor’s degree or higher in Mechanical Engineering.
Proven ability to own endtoend mechanical system design and delivery for BESS cabinets, racks, and containerized platforms, including sheetmetal and welded structures, cast and machined parts, polymers and elastomers, and durable outdoor coatings.
Strong handson experience designing, integrating, and validating electromechanical systems, including battery modules, highpower electrical components (PCBs, contactors, fuses, breakers), busbars and cable harnesses, with focus on safetycritical design, electrical clearances, manufacturability, and longterm serviceability.
Handson experience performing DFMEA, failure analysis (FA), and rootcause analysis (RCA) using 8D and whywhy methodologies and driving corrective and preventive design actions.
Strong background in DFA / DFM / DFX for injection molding, sheetmetal fabrication, stamping, milling, and turning, with continuous focus on cost, quality, and manufacturability.
Experience optimizing battery module and cell layouts within racks and containers for size, weight, installation, transportation, and longterm serviceability.
Working knowledge of global standards and compliance applicable to commercial and utility BESS, including:
UL 9540, UL 9540A, UL 1741, UL 1973, IEC 62933
NEC 706, NFPA 70, NFPA 855, 68 & 69, and relevant IFC and IEC standards
Enclosure standards: IEC 60529 (IP), NEMA, IEEE 693 / AC 156
Material and Enclosure Safety: UL 94, UL 746C, UL50 / UL 50E
Connector standards: UL 486A486B, UL 6703, IEC 61984, IEC 612381, EN 60512, EN 60352
Reliability testing: MILSTD810 environmental and mechanical methods
Experience supporting battery system certification, regulatory documentation, supplier engagement, and collaboration with AHJs.
Design experience for outdoor BESS enclosures with IP/NEMA ratings, C4/C5 corrosion protection, and durability targets exceeding 15 years.
Clear, concise, and effective written and verbal communication skills for global, crossfunctional collaboration, including manufacturing and suppliers.