Staff Mechanical Engineer

Smart Wires is reimagining the grid with our modular Flexible AC Transmission Systems (FACTS) solutions and analytics that enable controllable power systems. This means more renewables, at a lower cost and with less disruption to communities and the environment. We collaborate with our customers to achieve their strategic objectives and help them face an uncertain energy future with flexible, high-impact solutions.

Position Summary

The Staff Mechanical Engineer will play a critical role in the design, development, analysis, and validation of complex mechanical and electro-mechanical systems. You will contribute as a hands-on technical expert while providing technical leadership across projects, working through all phases of product development from conceptualization to production within a fast-paced, collaborative environment.

This role requires deep expertise in finite element analysis (FEA), thermal modeling, and vibration analysis, along with the ability to translate advanced simulations into actionable design improvements for robust, manufacturable, and reliable products.

Primary Responsibilities

- Collaborate with cross-functional engineering, manufacturing, project & services, and product development management teams to deliver robust design solutions while supporting prototype builds, analysis, testing, and field remedial activities.

- Build FEA and thermal/CFD models from scratch, working closely with design engineers across multi-disciplinary areas.

- Perform advanced simulations using ANSYS, ANSYS Fluent, or equivalent tools for FEA and thermal modeling, including static, dynamic, thermal, linear, and non-linear analyses on assemblies ranging from few to 800+ parts.

- Conduct dynamics and vibration analysis, including modal analysis, modal testing, and analysis of dynamically induced vibration for multi-body systems.

- Establish and lead subsystem test strategies for root cause analysis and simulation/verification/validation.

- Create clear, meaningful documentation to convey simulation results and design data.

- Provide hands-on troubleshooting and engineering support within a rapid development cycle.

- Apply GD&T and tolerance analysis in mechanical design and documentation.

- Support design solutions through all phases of development, from conceptual design to manufacturing release.

- Maintain a positive, collaborative approach with a strong, honest work ethic while mentoring junior team members as needed.

Requirements

Required skills and experience

- Bachelor’s or Master’s degree in Mechanical Engineering or a related field.

- 10+ years of proven experience with FEA and CFD simulations, including static, dynamic, thermal, linear, and non-linear analyses building complex multi-physics simulation models with ANSYS.

- Strong proficiency in using SolidWorks, SolidWorks PDM Vault, and SolidWorks Simulation Package to create design concepts, manage and generate detailed drawings and assemblies, analyze parts, and material.

- Competent in using Agile product lifecycle management (PLM) to manage BoM, ECO, MCO, CARs, work instructions, in-process testing, and reports.

- Good and in-depth knowledge of engineering materials especially aluminum, copper, polymers, and composites for fatigue, wear, impact, temperature extremes, dielectric insulations for high and medium voltages, coating for electrical insulators & conductors, corrosion of steel components, and aging due to long term exposure to weather.

- Experience in manufacturing processes such as welding, machining, sheet metal, casting, injection molding, and 3D printing.

- Knowledge of ASME Y14.5-2009 Dimensioning and Tolerancing (GD&T) standards and practices.

- Excellent written and verbal communication and presentation skills.

- Demonstrated success working in a collaborative team environment while mentoring and supporting peers.

Desired skills and experience

- PhD in mechanical engineering or related fields.

- Prior design and manufacturing experience at the Senior or Staff level working on FACTS devices, electro-mechanical systems, and large outdoor electrical enclosures.

- Proficiency in electromagnetic simulation/analysis using ANSYS for electro-mechanical systems.

- Coding/scripting skills using MATLAB, Python, or equivalent for analysis and automation.

- Experience working within ISO regulated environments.

Location

This role is located at the Smart Wires HQ, in (Research Triangle Park) Durham, NC

Benefits

At Smart Wires, we strive to foster an inclusive and supportive environment that focuses on our employees’ total wellbeing, and our benefit offerings reflect that commitment to our people.

We offer:

- Unlimited annual leave

- Paid volunteer time off to give back to your community.

- Eighteen weeks of paid parental leave to support you and your family.

- Competitive total compensation packages that include, salary, bonus and equity.

The Culture

We are passionate about creating a culture that empowers our team to create positive change for everyone and achieve their full potential, based on our core values:

Making an impact - We are passionate and ambitious about a better future for everyone. We are laser-focused on creating a meaningful, positive impact with real change for our customers, our industry, electricity consumers, and the planet.

Collaboration to drive success - We collaborate with each other, and our stakeholders, because we know even better outcomes come from great teamwork. We have humility because we know even better outcomes come from great teamwork. We have humility which allows us to listen, learn and improve. We value diverse perspectives and seek high impact results.

Accountability - We take responsibility for our actions and behaviors, and for the outcomes we deliver. Acting with integrity and authenticity – and maintaining clear, open communication – ensures we are always improving, and delivering safe, high-quality solutions. We do what we say we will do.

Tenacious courage - We are clear on our path. We have always pioneered new ideas that challenge the status quo, even when it’s not popular. We have tenacity, grit and determination. We push the boundaries of what’s thought to be possible – so we can leave the world a better place than we found it.

Smart Wires is committed to diversity in our organization and building an equitable and inclusive environment for people of all backgrounds and experiences. We provide equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability or genetics. Smart Wires complies with applicable federal, state and local laws governing nondiscrimination and we especially encourage members of traditionally underrepresented communities to apply, including women, people of any skin color, LGBTQ people, veterans, and people with disabilities.