Senior Mechanical Engineer - Sustaining

Position Summary

Responsible for sustaining the mechanical design of existing switch mode power supply products, with primary emphasis on end-of-life and obsolescence issues, material shortages, qualification of alternative mechanical parts and materials, failure analysis, implementation of approved engineering changes, and supplier-driven changes.

Duties & Responsibilities

• Provide mechanical sustaining engineering support for existing power supply products, primarily addressing material shortages, end-of-life or obsolescence, supplier changes, and internal mechanical quality or reliability issues.

• Evaluate alternative mechanical parts and chemical materials proposed by suppliers or component engineering team, including enclosures, chassis, covers, brackets, heatsinks, fans, thermal interface materials, plastics, sheet-metal parts, cast parts, machined parts, cables, connectors, gaskets, adhesives, potting materials, insulation, labels, fasteners, packaging, and PCB mechanical integration, etc.

• Support occasional mechanical aspects of transformers, inductors, magnet wires and other magnetic components in collaboration with electrical or component engineering.

• Review supplier drawings, specifications, samples, and technical proposals; assess fit, form, function, tolerance, material, thermal performance, manufacturability, quality, and reliability.

• Modify existing 3D models, assemblies, and 2D engineering drawings using appropriate mechanical CAD tools to implement sustaining design changes.

• Own the technical change from assessment through implementation, including mechanical risk assessment, prototype or sample review, qualification planning, design updates, and technical support for ECO/ECN implementation.

• Develop validation plans, coordinate or conduct mechanical tests, analyse results, document conclusions, and make technical decisions on alternatives and sustaining changes.

• Perform practical thermal assessments involving temperature measurements, heatsinks, fans, airflow, thermal interface materials, and validation of alternative parts or materials.

• Independently support mechanical failure investigations, including evidence collection, root-cause analysis, testing, validation, corrective actions, and technical documentation.

• Work closely with sourcing, quality, manufacturing, electrical engineering, and suppliers to resolve supplier-related technical issues. Provide manufacturing support mainly when issues arise from shortages, obsolescence, or alternative-material implementation.

• Bachelor's degree or above in Mechanical Engineering, Mechatronics Engineering, or an equivalent engineering discipline.

• Minimum 7 years of experience in mechanical design or sustaining engineering. Experience in the power supply industry preferred but candidates with relevant experience in comparable electronic products will also be considered.

• Proven experience supporting existing products through mechanical changes driven by material shortages, end-of-life or obsolescence, supplier changes, and quality or reliability issues.

• Proficient in SolidWorks and AutoCAD, with hands-on experience modifying 3D models, mechanical assemblies, and 2D engineering drawings.

• Strong knowledge of mechanical design principles, including tolerance, fit, form and function, material selection, manufacturing processes, and DFM/DFA considerations.

• Practical experience evaluating and qualifying mechanical parts and materials, reviewing supplier drawings and samples, and assessing supplier technical proposals.

• Proven experience in mechanical testing, failure analysis, troubleshooting, root-cause analysis, corrective actions, and validation documentation.

• Experience with practical thermal assessment, including temperature measurement, heatsink and fan evaluation, airflow review, thermal interface material selection, and thermal validation.

• Working knowledge of switch mode power supply architecture and mechanical-electrical interactions, including PCB integration, thermal paths, magnetic components, creepage and clearance, and EMI/EMC considerations.

• Experienced in engineering change management processes, including design updates and technical support for ECO/ECN implementation.

• General awareness of applicable mechanical safety, environmental, material, and product compliance requirements, with detailed assessment supported by compliance specialists.

• Proficient in English for technical communication and documentation; proficiency in Vietnamese or Chinese is an advantage.

• Familiar with Microsoft 365 applications, including Excel, PowerPoint, Teams, and SharePoint.

• Result-driven, detail-oriented, and committed to timely issue resolution and continuous improvement. Occasional travel may be required only when necessary.

XP Power provides a safe and healthy working environment that is stimulating and collaborative, where employees are empowered to make a real difference. We place our people at the heart of everything we do. We understand that if we provide our people with the ultimate experience, they will provide the ultimate experience to our customers.