Senior Staff Mechanical Engineer – DC/AC Interconnection for BESS

About the role

Enphase Energy is seeking a Senior Staff Mechanical Engineer to lead the mechanical design of high‑voltage DC and AC interconnection systems for utility‑scale inverters and Battery Energy Storage Systems (BESS). The role is based onsite in Bangalore and involves delivering production‑ready designs from concept through deployment.

Key responsibilities

• Own mechanical design of HV DC (800‑1500 V) and AC (277/480 V) interconnection hardware, including busbars, cable harnesses, bulkhead connectors, terminals, and insulation/barrier systems.
• Design custom bulkhead connectors and busbar layouts that meet creepage, clearance, and thermal‑expansion requirements.
• Integrate high‑current fusing, MCCBs, and molded case circuit breakers into the interconnection architecture.
• Develop IP‑rated electro‑mechanical solutions for outdoor cabinets and containerized platforms.
• Perform structural, thermal, and vibration analysis using FEM/FEA on plastics, aluminum extrusions, copper busbars, and other materials.
• Collaborate with electrical, controls, thermal, sourcing, manufacturing, and quality teams to ensure safety, reliability, manufacturability, and cost targets.

Required profile

• Extensive hands‑on experience in mechanical design of high‑voltage DC and AC systems for MW/MWh‑scale applications.
• Proven ability to deliver designs from concept to production while managing BOM cost.
• Strong understanding of safety compliance, creepage/clearance rules, and IP rating requirements.

Required skills

• Mechanical design of busbars, cable harnesses, bulkhead connectors.
• High‑voltage DC (800‑1500 V) and AC (277/480 V) interconnection expertise.
• FEM/FEA structural and thermal analysis.
• Material knowledge: injection‑molded plastics, aluminum extrusions, copper busbars.
• Design for IP‑rated outdoor equipment.
• Integration of high‑current fusing and MCCBs.