Mechanical Design Engineer

This role is a high-visibility position within the Industrial Solutions Engineering organization, supporting Sensata’s strategic investment in the data center market. The role focuses on the development, integration, and validation of thermal-magnetic circuit breaker solutions for data center infrastructure and new sensing applications.
The engineer will evaluate supplier and partner products, develop test and validation plans, and ensure solutions meet Sensata’s performance, reliability, and quality standards. The role includes close collaboration with contract manufacturing partners and certification teams to enable product qualification and certification under the Sensata brand, supporting scalable, high reliability control solutions for mission critical applications.
The Mechanical Design Engineer collaborates with a local team or global engineering team on product design which satisfy customer specifications. This process includes design, product validation, completing documentation and executing launch items for production. Complete all related drawings, documentation and release in internal systems.

General Responsibilities
• Leverages engineering fundamentals and organization to make sound decisions on complex technical issues
• Detailed understanding of market and implications for business
• Proactively challenge and drives the organization to deliver improved quality and performance related to engineering design
• Product Strategy participant and driver
• Maintain product documentation (drawings and specifications)
• Direct interaction with customers to solicit product specifications requirements, schedule expectations and budget
• Corrosion research and welding characterization & has a strong understanding of mechanical engineering principles, materials, mechanics, fluid, thermo and heat transfer
• Advanced knowledge of basic electrical circuits, microelectronic assembly, statistical methods, process control fundamentals and product test processes
• Familiarity with manufacturing methods – welding, brazing, soldering, adhesive bonding, machining, stamping, molding, and forming. Basic knowledge of core manufacturing processes
• Lead mechanical design activities while participating on cross-functional New Product Development (NPD) teams
• Assist with design prototype builds and production validation activities in collaboration with manufacturing, quality, and supply
• Familiarity with design, fabrication, modification, and evaluation in support of manufacturing operations such as machining, metal forming, plastics processing, welding and brazing, assembly, and material handling

Experience / Qualifications
• A university degree required (i.e. Bachelors degree) or equivalent relevant work experience
• Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands
• Strong communication skills; oral, written and presentation
• Strong organization, planning and time management skills to achieve results
• Strong personal and professional ethical values and integrity
• Holds self-accountable to achieving goals and standards
• Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel)
• Strong interpersonal & collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers

• Proven experience in the design of molded case circuit breakers (MCCB) and miniature circuit breakers (MCB), and Residual Current Device (GFCI/RCD)
• Strong expertise in thermal-magnetic trip mechanisms, including bimetal strip and magnetic trip design principles.
• Hands-on experience with operating mechanism system design, ensuring reliable and stable actuation performance.
• Solid understanding of contact system design, including contact materials, contact force, and electrical durability optimization.
• In-depth knowledge of arc extinguishing system design, such as arc chute structure and arc energy management.
• Ability to independently design and develop new circuit breaker products from concept to production.
• Familiarity with electromechanical integration, tolerancing, and reliability design for low-voltage switching devices.
• Experience in product validation, testing standards (UL489/UL1077UL1053/IEC60947/GB14048), and failure analysis for thermal-magnetic protection devices.
• Strong problem-solving skills with the ability to lead technical projects and work independently without supervision.
• Proficiency in 3D CAD tools (e.g., SolidWorks, Creo, or similar) and engineering simulation related to mechanical and thermal performance.

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