Battery Pack Mechanical Design Engineer II, Amazon Prime Air - Electric Propulsion Subsystem

We are seeking a Battery Pack Mechanical Hardware Development Engineer II to join our Drone Electric Propulsion Subsystem (EPS) team. In this role, you will be a significant and autonomous contributor, solving difficult hardware engineering problems related to battery systems. You will design, develop, and validate battery packs from concept through production, working on high-voltage battery systems that push the boundaries of performance, reliability, efficiency, and safety.

This position requires an engineer who demonstrates strong technical depth in battery pack design while also exhibiting the system-level thinking and influence characteristic of our most impactful contributors.

Key job responsibilities

Design & Development:

• Design mechanical architecture for high-voltage Li-Ion battery packs, including cell arrangement, modules, enclosures, structural supports, and interconnections.
• Create detailed 3D models and manufacturing drawings using CATIA with GD&T.
• Develop cell-to-module and module-to-pack packaging concepts balancing energy density, safety, and manufacturability.
• Design and integrate thermal management systems and sealed, IP-rated enclosures.

Analysis & Validation

• Perform FEA (structural, vibration, thermal) and tolerance stack-up analysis to validate designs.
• Plan and execute prototype builds, validation testing, and root-cause failure analysis.

Safety & Compliance

• Design to high-voltage safety requirements including creepage/clearance, isolation, and HVIL.
• Incorporate thermal runaway mitigation and ensure compliance with applicable standards (UN 38.3, UL 2580, IEC 62133, etc.).
• Develop verification test plans to verify designs against DO-160 and DO-274 standards
• Support DFMEA and design-for-safety activities.

Cross-Functional Collaboration

• Partner with electrical, BMS, systems, and safety engineers on mechanical and interface requirements.
• Coordinate with manufacturing, supply chain, and suppliers on DFM/DFA, tooling, and sourcing.
• Participate in and present at design reviews.

Documentation & Process

• Maintain engineering documentation and manage changes through PLM.
• Support project planning with estimates, timelines, and risk assessments.

Continuous Improvement

• Identify opportunities to improve cost, weight, safety, and manufacturability.
• Contribute to team design standards and best practices.