HV Battery Design & Release Engineer- Busbar-To Cell Welding/Array & Thermal

In this position...

Join the HV Battery Array team as a Design & Release Engineer. You will design, validate, and release high voltage (HV) battery array modules and work closely with cross-functional and global partners to bring them to production. You will also help establish Ford's new in-house laser welding capability for HV battery cells. In that work, you will own the specification and validation of the busbar-to-cell weld and support early plant trials. As the team's needs evolve, you will take on additional array and thermal design and release assignments.

At Ford Motor Company, we believe freedom of movement drives human progress. We also believe in providing you with the freedom to define and realize your dreams. With our incredible plans for the future of mobility, we have a wide variety of opportunities for you to accelerate your career potential as you help us define tomorrow's transportation. Do you have what it takes to make smart vehicles for a smart world? Join the Ford Product Development team. Utilizing Design Thinking and User Experience methods, you will work to deliver breakthrough products and services that delight our customers. We are seeking forward-thinking, laser-focused professionals with a passion for bringing innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to such advancements as autonomy, electrification, smart mobility technologies and more!

What you'll do...

• Work with CAD designers, CAE engineers, HV battery package engineers, suppliers, welding process engineers, and HV battery component engineers to design and release HV battery welded array modules. Where applicable, include teams in the UK, Brazil, and China.
• Develop and ensure compatibility of the electrical, mechanical, and thermal interfaces of the module within the HV Battery System.
• Design or evaluate supplier designs of specific module components. Use engineering techniques and knowledge of manufacturing processes to ensure the most efficient and cost-effective design.
• Work closely with other functions and global teams to meet package, performance, and attribute requirements for the HV Battery Array/Cell Block System.
• Ensure Design and Release activities are followed and completed. This includes release of HV battery array components in WERS, validation, issues management, quality document development, and delivery.
• Interface with adjacent teams, including the HV Battery unit team, HV Battery manufacturing team, HV Battery cell team, HV Battery Testing team, Supplier Technical Assistance, and Purchasing.
• Identify process and design improvements for efficiency and cost savings.
• Report design, testing, timing, and quality issues to leadership on a timely basis and lead technical resolution.

Laser Welding Focus Area

• Own and develop the engineering specification for busbar-to-cell laser welding. Take it through Battery Manufacturing Engineering (BME) review and release.
• Define the functional requirements of the welded joint for structural integrity, electrical conductivity, and thermal management.
• Develop and execute Design Validation (DV) and Process Verification (PV) test plans to support PPAP of the process assembly line.
• Work with BME to develop capability studies that prove the specification is met. Assess tradeoffs to minimize scrap, improve First Time Through (FTT), and improve cycle time.
• Support early plant trials and pre-production builds, including on-site work at the plant. Interpret real-world trial conditions and drive technical resolution.
• Review weld quality data, including cross-section analysis, and use it to refine process parameters and requirements.

What you'll do...

• Work with CAD designers, CAE engineers, HV battery package engineers, suppliers, welding process engineers, and HV battery component engineers to design and release HV battery welded array modules. Where applicable, include teams in the UK, Brazil, and China.
• Develop and ensure compatibility of the electrical, mechanical, and thermal interfaces of the module within the HV Battery System.
• Design or evaluate supplier designs of specific module components. Use engineering techniques and knowledge of manufacturing processes to ensure the most efficient and cost-effective design.
• Work closely with other functions and global teams to meet package, performance, and attribute requirements for the HV Battery Array/Cell Block System.
• Ensure Design and Release activities are followed and completed. This includes release of HV battery array components in WERS, validation, issues management, quality document development, and delivery.
• Interface with adjacent teams, including the HV Battery unit team, HV Battery manufacturing team, HV Battery cell team, HV Battery Testing team, Supplier Technical Assistance, and Purchasing.
• Identify process and design improvements for efficiency and cost savings.
• Report design, testing, timing, and quality issues to leadership on a timely basis and lead technical resolution.

Laser Welding Focus Area

• Own and develop the engineering specification for busbar-to-cell laser welding. Take it through Battery Manufacturing Engineering (BME) review and release.
• Define the functional requirements of the welded joint for structural integrity, electrical conductivity, and thermal management.
• Develop and execute Design Validation (DV) and Process Verification (PV) test plans to support PPAP of the process assembly line.
• Work with BME to develop capability studies that prove the specification is met. Assess tradeoffs to minimize scrap, improve First Time Through (FTT), and improve cycle time.
• Support early plant trials and pre-production builds, including on-site work at the plant. Interpret real-world trial conditions and drive technical resolution.
• Review weld quality data, including cross-section analysis, and use it to refine process parameters and requirements.