Senior Mechanical Engineer (Contract – Medical Power Electronics)Contract Duration: 3–6 monthsLocation: Onsite (Cork-Office based)Start Date: ASAP
Role Overview
Our Client is seeking a highly experienced Senior Mechanical Engineering Contractor to support the development and industrialization of high-voltage power supply assemblies used in regulated applications. Experience with medical-grade power electronic modules to IEC60601 would be a bonus but not essential.
This role requires an engineer who can hit the ground running, operate with minimal day‑to‑day input, and take ownership of mechanical design activities while aligning with an existing on‑site Senior Mechanical Engineer. The successful candidate will bring deep, hands‑on experience in tooling, tolerance analysis, and PCB‑to‑enclosure integration in safety‑critical electronic systems. Experience in plastics and soft tooling is a must.
Key Responsibilities
Mechanical Design for Medical Power Electronics
Design and develop mechanical solutions for medical power electronic modules, including:
Structural frames, metal panels and enclosures
PCB support and retention features
Patient and operator safety, electrical isolation and physical robustness
Manufacturability for low‑to‑medium‑volume medical builds
Soft Tooling (Medical Device Context)
Lead soft tooling efforts for:
Large plastic frames (A4 sized) used in medical electronic modules
Metal panels and covers used in power electronics assemblies
Work directly with tooling vendors to:
Enable rapid iteration and controlled changes
Resolve fit, warp, cosmetic, and tolerance‑related issues
Ensure tooling choices are appropriate for medical NPI or pilot production environments.
Tolerance & Mechanical Stack‑Up Analysis
Perform and document mechanical tolerance stack‑ups for:
Modular power electronics architectures
Identify mechanical risks impacting connector mating and alignment
Enclosure stack‑up and fastener preload
PCB‑to‑enclosure mounting points
Connector alignment (HV, LV, signal)
Enclosure closure interfaces (covers, frames, seals)
Isolation barriers and insulating features
External interfaces (mounting feet, chassis rails, cable exits)
Provide clear, defensible analyses suitable for design reviews and regulated documentation.
PCB & Enclosure Integration (High Voltage, Medical Safety)
Integrate A4‑sized PCBs into mechanical housings with focus on:
High‑voltage insulation and spacing
Mechanical protection of HV components
Isolation barriers and insulating features
Number and location of mounting points
Fixed vs floating mounts (slots vs round holes)
Over‑constraint risk (especially with large A4 PCBs)
Ability to absorb tolerance and enclosure distortion
Long edge support vs point support
Local stiffening needed near connectors or heavy components
Need for secondary supports (insulators, pillars, ribs)
PCB warp tolerance considered in stack
Enclosure flatness vs PCB flatness assumptions
Interaction between fastener pull‑down and PCB bending
Design enclosures compatible with:
Thermal management needs of power electronics
Service access and controlled replacement
Medical safety expectations (finger‑safe, shielding, robustness), detail drawings
STEP and neutral file exports
CAD, Drawings & Design Control
Organize and rationalize existing CAD data into a clean, controlled structure, including:
Assembly models
Ensure drawings:
Clearly convey design intent
Align with medical device design control expectations
Operate autonomously while aligning with the on‑site Senior Mechanical Engineer on:
Risk trade‑offs and escalation items
Collaborate effectively with:
Electrical engineering
Manufacturing and suppliers
Quality and regulatory stakeholders as needed
Deliver designs and documentation within aggressive project timelines.
Required Qualifications & Experience
6+ years of mechanical engineering experience, preferably in:
Proven hands‑on experience with:
Soft tooling for plastic frames and housings
Soft tooling for metal panels or enclosures
Strong competency in mechanical tolerance analysis for complex electronic assemblies.
Extensive experience integrating large PCBs into enclosures for high‑voltage power applications.
Proficient in professional 3D CAD tools (specifically SolidWorks).
Ability to work with minimal supervision and make sound technical decisions in alignment with the on‑site Sr. Mech Eng. Power electronics
Safety‑critical electronic systems
Medical devices (Nice to have)
Familiarity with medical device safety standards impacting mechanical design (e.g., IEC 60601 concepts such as spacing, accessibility, and enclosure integrity).
Experience supporting medical NPI, pilot builds, or design transfer activities.
Prior contract or consultancy experience in regulated environments.
Personal Attributes
High degree of English competency with excellent spoken and written English.
Proven ability to communicate complex mechanical concepts clearly and concisely to electronic, manufacturing and quality stakeholders.
Capable of producing clear, unambiguous technical documentation (e.g., drawings, tolerance analyses, design notes, etc.).
Highly self‑directed and execution‑focused.
Detail‑oriented with strong appreciation for manufacturing and safety constraints.
Clear communicator capable of concise documentation suitable for a regulated product environment.
Duration: 6 months (potential move to permanent)
Work Model: Primarily onsite to enable effective collaboration (hybrid considered)
#J-18808-Ljbffr