Design Engineer – Generator Packaging & Enclosures
Location – Northbrook, IL (Remote within the U.S.)
Compensation
• Base Salary: $110,000 – $125,000
• Annual Bonus: Up to 20%
• Full benefits package
Our client, a leading provider of mission-critical power solutions for data centers, is seeking a Design Engineer to engineer complete physical packages surrounding large diesel generator sets (150 kW – 2 MW). This role focuses on transforming base CAT generator sets into installation-ready power packages through enclosure design, structural integration, cooling/airflow engineering, and acoustic attenuation. This is a hands-on leadership role with full responsibility for shop performance, team leadership, production flow, and customer satisfaction.
This is a remote opportunity for candidates with strong generator packaging, sheet metal, weldment, and CAD experience—ideally with CAT genset exposure.
Key Responsibilities
Generator Enclosure & Structural Design
• Design weather-protective, walk-in, sound-attenuated, and custom generator enclosures.
• Engineer structural bases/skids and weldments to support engines, alternators, radiators, fuel systems, and ancillary equipment.
• Create sheet-metal design and fabrication drawings for doors, panels, louvers, access points, and equipment mounting.
Cooling, Airflow & Acoustics
• Perform cooling and airflow engineering: radiator airflow, intake/exhaust ventilation, louvers, ducting, and heat rejection.
• Design acoustic attenuation systems to meet specified dBA requirements without restricting cooling airflow.
Systems Integration
• Package exhaust systems including mufflers, piping, supports, and aftertreatment components.
• Integrate fuel systems: base/day tanks, fill connections, and associated piping.
• Ensure proper engine and alternator integration with correct component clearances.
• Design vibration isolation, mounting, and structural considerations.
• Integrate controls, breakers, switchgear, ATS connections, wiring pathways, and cable-entry locations.
Manufacturing & Documentation
• Create 3D models, fabrication drawings, BOMs, and manufacturing documentation.
• Collaborate directly with fabrication, welding, and assembly teams to ensure designs are buildable.
• Reverse-engineer or redesign existing/remanufactured CAT generator packages for customer-specific applications.
• Support reliability and repeatability requirements for data-center and mission-critical power projects.
Required Qualifications
• Bachelor’s degree in Mechanical Engineering or related field (or equivalent experience).
• 5+ years of experience in mechanical design, generator packaging, or power generation engineering.
• Proven experience with diesel generators, sheet metal/weldments, enclosures, airflow/cooling, and acoustics.
• Advanced proficiency in CAD software (SolidWorks, Inventor, or similar) for 3D modeling and fabrication drawings.
• Strong understanding of fabrication/manufacturing processes, including welding, sheet metal, and structural design.
• Experience with cooling/airflow engineering, acoustic attenuation, and vibration isolation.
• Familiarity with fuel systems, exhaust systems, and electrical integration (switchgear, ATS, controls).
Preferred Qualifications
• CAT Genset design experience (150 kW – 2 MW range).
• Experience in data center or mission-critical power applications.
• Knowledge of weather resistance, sound insulation, and service access requirements for generator enclosures.
