Electronics Packaging Design Engineer

Position description:
The Mechatronics & Electronics packaging engineer will design and release the mechanical enclosures and packaging of automotive mechatronic products in the EV/HEV portfolio - motor controllers, VCUs, chargers, DC-DC units, charging stations, etc. so that the electronics and electrical components inside them are correctly protected, cooled, sealed, mounted and serviceable. The role will ensure that designs are manufacturable, cost-effective and validated to automotive environmental and durability requirements. The role owns the mechanical design from concept and CAD through tolerance analysis, prototype build and validation to tooling release and series change management.
About TVS / Who are we?
TVS Motor Company is a reputed two and three-wheeler manufacturer globally, championing progress through Sustainable Mobility with four state-of-the-art manufacturing facilities in Hosur, Mysuru and Nalagarh in India and Karawang in Indonesia. Rooted in our 100-year legacy of Trust, Value, and Passion for Customers and Exactness, we take pride in making internationally aspirational products of the highest quality through innovative and sustainable processes. We are the only two-wheeler company to have received the prestigious Deming Prize. Our products lead in their respective categories in the J.D. Power IQS and APEAL surveys. We have been ranked No. 1 Company in /the J.D. Power Customer Service Satisfaction Survey for consecutive four years. Our group company Norton Motorcycles, based in the United Kingdom, is one of the most emotive motorcycle brands in the world. Our subsidiaries in the personal e-mobility space, Swiss E-Mobility Group (SEMG) and EGO Movement have a leading position in the e-bike market in Switzerland. TVS Motor Company endeavours to deliver the most superior customer experience across 80 countries in which we operate.
For more information, please visit www.tvsmotor.com.
Job Title / Role: Electronics Packaging Design Engineer
Department: R&D-EV Sys D&D
Location: Hosur
Education Qualification: B.E. / B.Tech / M.E. / M.Tech in Mechanical, Mechatronics, Automotive or Production Engineering
Required Experience: 6 - 10 years in mechanical design for electronic and mechatronic products. Electronics enclosures, controllers, EV chargers, docking or battery swapping stations. At least two or more products taken from concept to series production.
Role Description
Accountability: Mechanical Design and Packaging of Electronic Assemblies
Tasks:
Develop mechanical concepts and detailed designs for enclosures and housings of EV controllers, chargers, charging stations. Balancing electrical, thermal, EMC, cost and serviceability needs.
Package PCBs, power modules, busbars, connectors, sensors, cables and cooling elements within the available envelope, including creepage/clearance and HV isolation distances.
Design mounting, fixing, grounding, strain-relief and interface features to the vehicle or the station structure.
Own the mechanical design change loop with the electronics, thermal and system teams and drive concept selection through design reviews.
Accountability: CAD Modelling, Drawings, GD&T and Tolerance Analysis
Tasks:
Create and maintain parametric 3D models and assemblies in PTC Creo / CATIA following the applicable modelling standards.
Release 3D and 2D manufacturing drawings with complete and correct GD&T and inspection-ready dimensioning.
Perform worst-case and statistical tolerance stack-up analysis for critical fits, sealing surfaces, connector alignment and thermal interfaces.
Maintain models, drawings, BOMs and revisions in the PLM system (Windchill).
Accountability: Design for Manufacture, Assembly and Material / Process Selection
Tasks:
Select materials and manufacturing processes appropriate to volume, cost and performance.
Apply DFM and DFA principles: draft angles, wall thickness, ribs, parting lines, fastener count and separation and assembly sequence.
Be the champion for part scalability, modularity and cost reduction.
Work with tool makers and suppliers on tool feasibility, moldflow feedback, tolerance capability and troubleshooting.
Own the DFMEA for the mechanical design and drive the resulting design actions to closure.
Accountability: Thermal, Sealing, Structural and NVH Design Integration
Tasks:
Design the thermal interface for power electronics components: heat sinks, cooling path, thermal interface materials, potting and fan integration.
Design sealing and ingress protection concepts (gaskets, O-rings, adhesives, breathers, vents) to meet IP targets and validate them by test.
Define and verify structural and vibration performance of housings, brackets and mounts: interpret FEA and CFD studies with the CAE team.
Address NVH, thermal expansion, corrosion protection, surface treatment and material compatibility in the design.
Accountability: Prototype Build, Testing and Design Validation
Tasks:
Plan and support prototype and pre-series builds, including rapid prototyping, fixtures, assembly instructions and build issue resolution.
Define the mechanical DVP: vibration, mechanical shock, drop, thermal cycling and shock, salt spray, dust and water ingress and durability testing.
Analyse test results and field/warranty issues. Perform root-cause analysis and implement design countermeasures.
Accountability: Supplier, Tooling and Documentation Support
Tasks:
Support supplier selection and technical evaluation for castings, mouldings, sheet metal parts and assemblies.
Release and manage engineering change notes, deviations and BOM updates through to series implementation.
Maintain design guidelines, standard parts libraries and lessons learned for electronic packaging.
Support cost, weight and packaging target tracking together with purchasing and program management.

Work arrangement
Hybrid