Staff HW Development Engr (Mech. Design)

As a Staff Mechanical Design Engineer in our Optical Networks Product & Solutions Engineering HW & Test team, you will be instrumental in the end-to-end mechanical design and development lifecycle of our products. This role involves conceptualizing, designing, analyzing, and validating mechanical solutions for modular systems, chassis, and rack infrastructure. You will leverage your expertise in materials, manufacturing processes, and advanced CAD tools to deliver robust, reliable, and compliant designs, collaborating closely with cross-functional teams from initial concept through to production and environmental qualification.

• BE / BTech / MTech in Mechanical Engineering with 4–12 years of relevant work experience.
• Strong knowledge and practical experience in mechanical design within the telecom domain.
• Proven ability to design line cards for modular systems, various types of heat sinks and their mounting mechanisms, fixed system chassis (1-42 RU), and rack designs compliant with ETSI / NEBS requirements.
• In-depth understanding of sheet-metal and machining operations.
• Proficiency in performing tolerance stack-up analysis with strong GD&T knowledge.
• Hands-on experience with CREO for sheet metal, casting, plastics, and fiber routing.
• Working knowledge of PLM tools such as Windchill and Agile.
• Capability to exchange data with ECAD using DXF / EMN / EMP formats.
• Ability to perform hand calculations for forces during line card insertion/extraction and heat sink mounting.
• Demonstrated ability to work independently and collaboratively with Marketing, Design, and Testing teams for reviews.
• Experience in conducting mechanical tests such as form-fit-function and first-article inspection.
• Understanding of operational and non-operational environmental qualification requirements.

Desirable Skills:

• Knowledge of thermal analysis principles and experience with tools like Flotherm.
• Experience in mechanical design aligned with EMI requirements.
• Strong materials knowledge for sheet metal, casting, and plastics applications.
• Familiarity with structural analysis and tools such as Ansys or LS-DYNA.
• Design and develop mechanical components and systems, including line cards for modular systems, various types of heat sinks and their mounting mechanisms, and fixed system chassis (1-42 RU).
• Create rack designs adhering to ETSI and NEBS requirements.
• Apply strong knowledge of sheet-metal and machining operations in design for manufacturability.
• Perform tolerance stack-up analysis and apply Geometric Dimensioning and Tolerancing (GD&T) principles.
• Utilize CREO for hands-on design of sheet metal, casting, plastics, and fiber routing.
• Manage product data using PLM tools such as Windchill and Agile.
• Facilitate data exchange with ECAD teams using formats like DXF, EMN, and EMP.
• Conduct hand calculations for critical forces, such as line card insertion/extraction and heat sink mounting.
• Collaborate effectively with Marketing, Design, and Testing teams throughout the product development cycle.
• Plan and execute mechanical tests, including form-fit-function (FFF) and first-article inspection (FAI).
• Ensure designs meet operational and non-operational environmental qualification requirements.