Battery Design Engineer
On-sitePalo Alto, California, United States
Job Summary
Own complex battery subassemblies or full systems from concept through production launch, integrating structural, thermal, electrical, and packaging requirements into cohesive hardware. Design and release top-level assemblies, including 2D drawings with rigorous GD&T, while balancing constraints across enclosures, busbars, cooling systems, and structural components. Rapidly down-select concepts using first-principles analysis and hands-on prototyping, then work directly with suppliers and contract manufacturers on tooling, process development, and production ramp. Root-cause manufacturing and field issues across mechanical, thermal, and electrical domains to ensure scalable, safe, and reliable battery systems.
Required Qualifications
- BS in Mechanical Engineering or related field
- Ability to bound problems from first principles — thermal, structural, and electrical — with back-of-envelope calcs before reaching for simulation tools
- Proven track record designing and releasing complex electromechanical products from concept through production — battery packs, high-density electronics packaging, or similarly constrained assemblies
- Fluency with advanced 3D modeling software
- Ability to produce production-quality 2D drawings with rigorous GD&T
- Manufacturing process knowledge: welding, stamping, molding, fasteners, adhesives, TIMs, and mechanical joining — with DFM and DFA instincts applied from the first concept, not the last review
- Hands-on builder — comfortable in the lab prototyping, debugging, and validating hardware directly, not just reviewing test reports
- Working knowledge of how cell behavior, thermal limits, and electrical integration drive pack mechanical architecture
- Experience with FEA (structural and thermal) tools such as Ansys or Altair
Desired Qualifications
- CATIA V6 / 3DX
- Experience designing battery packs for EVs, powersports, micromobility, or other electrified platforms
- Experience with automated manufacturing and high-volume assembly systems
- Familiarity with lithium-ion cell characterization and selection
- Experience working directly with Asian suppliers or contract manufacturers
- Experience supporting factory launch or production ramp activities
- Familiarity with battery safety and abuse testing standards
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