ORS Partners

  • Mechanical Engineer

    Job Locations US-MA-Boston
    # of Openings
    Architecture and Engineering (non-IT)
  • Overview

    XL seeks a mechanical engineer to perform design, development, and production support of mechanical powertrain components and systems for commercial hybrid electric vehicles. This person will be a core technical contributor of the R&D team and assist mentoring interns.


    • Conduct and collaborate on the design of mechanical components for commercial hybrid electric vehicles including:
      • Custom frame cross members
      • Custom drive shaft components (spline shafts, u-joints, tube shafts, slip yokes, bearings, boots)
      • Custom components for traction motor interfacing (transmission adapters, integrated shafts)
      • Mounting brackets for traction motors, inverters, and lithium battery packs
      • Mounting brackets for auxiliaries including cooling system components (pumps, reservoirs, radiators) and microcomputers
      • Routing of cooling hoses, high voltage, and low voltage wiring
    • Adapt current products to new vehicle platforms driving for commonality and modularity where cost effective
    • Develop design strategies to address a wide variety of commercial vehicle platforms
    • Perform mechanical and thermal analysis and develop models to predict component and system behavior
    • Perform testing to validate component and subsystem designs including management of subcontracted efforts
    • Perform integration of mechanical systems into prototype vehicles and subsequent road testing to verify designs for production
    • Develop and manage prototype component suppliers including quoting and ordering
    • Perform Design to Value and Design for Manufacturing analyses
    • Manage R&D procurement and validation schedules to meet established platform development objectives
    • Support production transition including development of production suppliers
    • Support configuration control of the hybrid system bill of materials
    • Support development of installation and maintenance instructions
    • Mentor interns and coops as required
    • Collaborate on projects with the rest of the team, and draw on senior staff for advice, mentoring, and application of good standards for documentation and processes
    • Candidate will report to the VP of Engineering


    • B.S. in mechanically focused engineering discipline
    • Proficient in SolidWorks solid model CAD, file management, and drawing release
    • Demonstrated design to production experience
    • Must be able to work full time in XL Hybrids’ Boston office
    • Must be able to travel out of state on average <10%, but with offsite testing or conference events that may occasionally span a week

    Preferred Qualifications

    • 3+ years of mechanical design experience
    • Direct hybrid vehicle development experience
    • Direct automotive design or technician experience
    • Previous powertrain work experience for a major vehicle OEM
    • Proficient in structural, vibration, and thermal analysis finite element and/or CFD tools


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