We're looking for an experienced mechanical engineer to take ownership of battery pack and module design from concept through production. This is a senior individual-contributor role: you'll drive design decisions independently, lead thermal and structural analysis efforts, and mentor junior engineers, while working closely with electrical, controls, and manufacturing teams to ship real hardware.
Deep experience with thermal analysis and simulation is strongly preferred. We run active thermal test campaigns and simulation workflows, and this role owns that work rather than just supporting it.
What you'll do
Battery Mechanical Design
Own mechanical design of battery modules and packs end-to-end, including:
Cell integration concepts (prismatic, cylindrical, or pouch formats)
Structural components, brackets, and enclosure design
Busbar and interconnect geometry
Drive design reviews, tolerance stack-up analysis, and DFM decisions
Define mechanical interfaces across the assembly and negotiate trade-offs with electrical and controls teams
Make final calls on design trade-offs balancing performance, cost, and manufacturability
Thermal Analysis
Own thermal simulation setup, execution, and post-processing (SimScale, ANSYS, or equivalent)
Evaluate and select TIM and interface materials based on performance and cost trade-offs
Design and run thermal test campaigns; independently analyze discharge data and identify root causes of thermal issues
Correlate simulation outputs to physical test results and refine models accordingly
Testing & Validation
Define and lead mechanical validation test plans, vibration, drop, thermal cycling
Own root cause analysis on test findings and drive corrective actions to closure
Review and approve test reports and documentation from junior engineers
Documentation, Process & Mentorship
Maintain CAD revision history and BOM structure for your subsystems
Author engineering documentation, test procedures, and work instructions
Lead design review discussions and drive action items to closure
Mentor Mechanical Engineer I/II staff on CAD practices, GD&T, and design fundamentals
Required Qualifications
Bachelor's degree in Mechanical Engineering or closely related discipline
5+ years of professional mechanical engineering experience, ideally in battery, EV, or energy storage hardware
Demonstrated track record taking designs from concept through production
Expert-level 3D CAD skills (Onshape, SolidWorks, or equivalent)
Strong command of GD&T, tolerance stack-up analysis, and DFM principles
Experience owning mechanical subsystems independently, with minimal oversight
Ability to mentor junior engineers and lead design review discussions
Preferred Qualifications
Proficiency with FEA or CFD tools (SimScale, ANSYS, SolidWorks Simulation) for thermal and structural analysis
Direct experience with battery-powered devices, EV systems, or energy storage products