Senior Mechanical Engineer (Design)

Durham, NC


Job Summary:

The primary duty of the Sr Mechanical Engineer is to provide experienced mechanical design and engineering support for our Microgrid Mechanical Products such as low and medium voltage distributed energy resources (DERs) manufactured at our Durham, NC and Randleman, NC facilities. This position will assist the overall team to meet the departmental mission of providing deliverables and designs; while ensuring quality, time, and safety.

Minimum Qualifications: (Education, Experience, Knowledge, and Skills):

  • (4) Year Degree in Mechanical Engineering or related field (MSME or PE licensure a plus).

  • 10+ years of experience in related engineering role.

  • 10+ years of equivalent manufacturing experience with production of Generators, Power Equipment Centers, and Switchgear.

  • Experience in project engineering and/or coordinating project deliverables from a team lead perspective.

  • Proficient with 3-D CAD software, preferably AutoDesk Inventor Professional, Inventor Professional Stress Analysis and NASTRAN add-on for Inventor.

  • Proficient with MS Office applications: Outlook, Word, Excel, PowerPoint, etc.

  • Proficient with ERP/PLM environments

  • Experience with CFD modeling.

  • Strong verbal and written communication and interpersonal skills, including collaborating with other teams and providing constructive feedback.

  • Detail-oriented and accurate with a positive can-do attitude maintained in a fast-paced work environment.

  • Ability to critically analyze problems and develop effective solutions.

  • Excellent time management, leadership, organization, and prioritization skills.

  • Ability to travel occasionally (1-3(10%-15%) times per year).

  • Teachable with the subject matter, codes and standards, and competitive landscape to continue to learn and grow as an engineer.

  • A willingness to learn from other staff on good engineering and design practices and principles.

  • Hands-on: willing to get your hands dirty for the benefit of the team and to further our overall goals of legitimate engineering practices. The successful candidate will actively participate in the design process in both the office and manufacturing floor.

Job Duties and Responsibilities:

  • Work as part of the Microgrid Mechanical Engineering team for the modeling and creation of production drawing sets of the mechanical systems per specifications.

  • Provide engineering/design support for components and assemblies of the DI products including:

  • Generator Enclosures: Skintight steel interlocking panels, aluminum skinned stick-built enclosures, sound attenuating features.

  • Frame design: engine/alternator steel baseframes, SCR/Silencer mounting frames, aluminum enclosure frames, enclosure steel baseframes.

  • Fuel Tank Design: UL142 diesel fuel tank designs, including placement of nozzles, instrumentation, and other ancillary equipment.

  • Switchgear frames, bussing, breaker support structures, lug pads, and other ancillary features.

  • Develop document set; including BOM, schematics, schedules, and other drawing details that will ensure the safe and efficient installation of this equipment. Ensure drawings are as-built, documents and manuals are filed on the server for use in O&M development.

  • Develop CAD models to automatically drive complete BOMs in PDM software with proper product structures, assortments, and other metadata.

  • Perform calculations, both by hand and using computer, for various parameters such as fluid flow, friction, CFD, FEA, etc.

  • Interface with design team for placement and code clearances of electrical and mechanical equipment.

  • Assist with Product Development initiatives including new component design, fitment, etc.

  • Design for Manufacturability, reliability, field maintainability.

  • Identify and execute processes that may reduce the overall cost to manufacture, install and operate our electrical infrastructure systems located on our generator and switchgear enclosure products.

  • Coordinate with technical project managers to reduce scope gaps, identify project risk items, and support other team members through communication with project managers or other stakeholders.

  • Experienced with cradle to grave project execution.

  • Work with a SME from product management to facilitate product line improvement initiatives, own product development efforts from a design standpoint and coordinate with team manager and other engineering resources throughout.

Physical Demands and Work Environment:

  • While performing the duties of this job, the employee is occasionally required to stand; walk; sit; use hands to finger, handle, or feel objects, tools or controls; reach with hands and arms; climb stairs; talk and hear. The employee must occasionally lift and/or move up to 40 pounds. Specific vision abilities required by the job include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus. Must be able to work in front of screens for extended periods. Occasional exposure to and requirement to work around electrical testing, metal welding, forming, cutting and other industrial processes, often outdoors. Occasionally required to inspect in-process work. Must be able to position oneself in various positions including low to the ground or high up on equipment. The employee must be able to walk outside short distances between the manufacturing plant and offices in addition to standing on manufacturing floor for a few hours at a time.

  • Employee must be able to travel by car or commercial airline approximately 10-15% of the time.

  • The work environment includes ambient room temperatures, well-lit work areas and traditional office equipment as found in a typical office environment. Office environment with shared spaces. Employee will also be required to go to the manufacturing floor to gather information needed to complete job as needed.

About Us:

PowerSecure, a Southern Company subsidiary, is a leading provider of innovative energy solutions to electric utilities and their industrial, institutional, and commercial customers.

Join Our Power Team! (

We invest in high-value and cost-effective benefits for our employees. Our benefits package includes:

  • Medical, dental, vision and life insurance coverage

  • Competitive pay and a matching 401 (k) plan

  • Vacation, Company Holidays, Paid Time Off (PTO- personal and sick days)

  • Flexible spending accounts/Health savings account

  • Wellness Incentive Programs

  • Employee Referral Program

  • Tuition Reimbursement

PowerSecure is an Equal Opportunity/Affirmative Action employer and will consider all qualified applicants for employment without regard to race, color, religion, gender, sexual orientation, gender identity, national origin, age, protected veteran status, or disability status. This position is not open to third party recruiters.

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities

The contractor will not discharge or in any other manner discriminate against employees or applicants because they have inquired about, discussed, or disclosed their own pay or the pay of another employee or applicant. However, employees who have access to the compensation information of other employees or applicants as a part of their essential job functions cannot disclose the pay of other employees or applicants to individuals who do not otherwise have access to compensation information, unless the disclosure is (a) in response to a formal complaint or charge, (b) in furtherance of an investigation, proceeding, hearing, or action, including an investigation conducted by the employer, or (c) consistent with the contractor’s legal duty to furnish information. 41 CFR 60-1.35(c)Operating Company: PowerSecure