. Title: Principal Mechanical Design Engineer - Electrical Equipment Enclosures Company: Global Power Components – www.globalpowercomponents.com Location: Milwaukee, WI (onsite 5-days/week) Hire Type: Direct Hire Position Summary: Global Power Components is seeking a Principal Mechanical Design Engineer to provide expert technical leadership for the mechanical design and analysis of electrical power distribution enclosures. This role will own enclosure integrity, short-circuit withstand, thermal management, simulation, and design validation. The engineer will work directly with product development, certification, and manufacturing teams to turn new equipment concepts into safe, repeatable, production-ready designs. Key Responsibilities: Enclosure Design and Technical Ownership • Own the structural and mechanical design of enclosures, frames, doors, covers, barriers, mounting structures, bus supports, and bracing systems for electrical power distribution equipment. • Translate electrical ratings, short-circuit requirements, thermal loads, environmental requirements, and manufacturing constraints into robust mechanical designs. • Establish structural and thermal design criteria, safety margins, calculation methods, and reusable engineering standards across product families. • Make material, thickness, joining, fastening, gasketing, and reinforcement decisions based on analysis, testing, cost, and manufacturability. Simulation, Analysis, and Test Confidence • Lead finite element analysis of short-circuit forces, structural loading, stress, deformation, vibration, and dynamic response using ANSYS or comparable simulation software. • Lead thermal and airflow analysis to predict heat rise, hot spots, ventilation performance, and component or bus temperature limits. • Develop simulation models that represent actual enclosure construction, joints, supports, materials, bus structures, and boundary conditions. • Correlate simulation results with prototype and laboratory test data, then continuously improve model accuracy and design rules. • Use analysis to identify design risk before certification testing and recommend changes that improve the probability of passing on the first test. Validation, Certification, and Manufacturing Integration • Own the mechanical and thermal portions of verification plans, design reviews, instrumentation, acceptance criteria, and failure analysis. • Provide mechanical and thermal technical leadership before, during, and after product and certification testing. • Partner with the product-development engineer to meet product-layout and performance requirements while developing and validating the enclosure and structural design. • Work directly with manufacturing on sheet metal fabrication, welding, hardware, assembly, finishing, prototypes, first builds, and design-for-manufacturing improvements. • Document assumptions, calculations, analysis results, design decisions, and lessons learned so they become part of the product-development system. Qualifications Required: • Bachelor's degree in Mechanical Engineering or a related engineering discipline. • Twelve or more years of direct design experience with enclosures for electrical power distribution equipment. • Demonstrated expertise using ANSYS or comparable simulation software for structural, dynamic, or short-circuit-force analysis. • Experience modeling thermal performance, airflow, heat transfer, and temperature rise in enclosed electrical equipment. • Experience owning the mechanical design of enclosures and structures through analysis, prototype, certification testing, and production release. • Deep knowledge of fabricated sheet metal structures, welded assemblies, bolted joints, fasteners, materials, tolerances, and design for manufacturing. • Ability to make and defend technical decisions using calculations, simulations, test evidence, and sound engineering judgment. Preferred: • Experience designing switchgear, switchboards, motor control centers, busway, panelboards, or other high-current electrical equipment. • Experience analyzing electromagnetic short-circuit forces and the mechanical response of bus supports, barriers, and enclosures. • Experience with coupled structural and thermal simulation, CFD, multiphysics analysis, or nonlinear contact analysis. • Experience preparing designs for UL, IEEE, ANSI, NEMA, IEC, or related certification and high-power laboratory testing. • Experience building simulation methods and design standards for a new or expanding product platform. Success Profile: • Is a true technical expert who uses engineering tools and evidence to reduce design and certification risk. • Does not rely on excessive material or conservative sizing as a substitute for analysis. • Balances short-circuit performance, thermal performance, manufacturability, cost, and scalability. • Remains hands-on with models, calculations, designs, prototypes, and laboratory testing. • Establishes reusable methods that raise the technical capability of the broader engineering team.