Battery Safety Simulation & Test Engineer
$134,100–$184,300 year
On-siteSan Carlos, California, United States
Job Summary
Develop coupled electrochemical, thermal, and gas-generation cell models to inform design parameters and cell technology roadmaps. Perform thermal analysis and simulations using lumped-sum models, CFD, and multi-physics tools to evaluate cell, module, and pack-level behavior under abuse scenarios. Own test planning, design, and execution for battery performance and safety, with a focus on high-voltage and thermal management. Correlate simulation results with experimental test data, refining models for accuracy and utility. Design, set up, and maintain complex test equipment, including electrical, mechanical, fluid systems, and data acquisition instrumentation. Drive decisions by analyzing and presenting data-driven insights and leading cross-functional efforts across battery, systems, and certification engineering teams. Support certification efforts across all programs by conducting tests, maintaining meticulous documentation of test plans, results, and observations.
Required Qualifications
- BS + 3 years of experience or MS + 1 year of experience in mechanical engineering, thermals, physics, or related field
- Solid understanding of cell / battery hazards and failure modes (e.g., thermal runaway, electrical shorts, mechanical abuse)
- Strong problem-solving mindset and foundation in thermodynamics, heat transfer, fluid dynamics, and electrical engineering fundamentals
- Willingness to get hands dirty and work with team-members on all levels of test execution, from planning to final cleanup
- Fundamental understanding of sensing and data acquisition principles
- Great written, verbal, and presentation skills
Desired Qualifications
- Advanced degree in a relevant engineering or science field and 5+ years of experience
- Strong fundamentals in Li-ion cell design, modeling, and testing for both nominal and abuse scenarios
- Knowledge of li-ion cell technology and experience with battery testing/design
- Experience working with abuse testing at cell/module/pack levels and familiarity with safety testing standards such as UN 38.3, SAE 2464, RTCA DO-311
- CAD experience, CATIA preferred
- Python or other language for data processing and visualization
- LabVIEW or other language for interfacing with data acquisition hardware
- Hands-on experience with thermal modeling and simulation tools such as ANSYS Fluent, COMSOL, STAR-CCM+, MATLAB/Simulink, or similar CFD/FEA software
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