Principal Engineer - EV Battery Systems

Location: Irvine, California

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Position Summary

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We are seeking a Principal Structural & CAE Durability Engineer to lead structural integrity, fatigue, and durability analysis for battery module and pack systems supporting next-generation EV and energy storage programs. This senior technical leadership role owns the CAE strategy, analysis methods, and automation roadmap for structural and durability engineering, mentors engineers across the team, and partners closely with Design Release Engineers (DREs) and cross-functional engineering groups to ensure battery structural designs meet performance, reliability, and manufacturability requirements. The ideal candidate brings deep expertise in FEA-based structural and durability analysis, a proven track record developing analysis automation tools, and experience applying AI/ML techniques to advance CAE capability.

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Essential Duties & Responsibilities

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2. Lead structural, fatigue, durability, and NVH CAE analysis for battery module and pack designs, including vibration fatigue (random PSD, sine dwell/sweep), weld fatigue (spot, laser, staple, MIG), and thermal cycling creep/fatigue of polymeric components.
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4. Define and drive the structural/CAE analysis strategy, methods, and technology roadmap across battery engineering programs.
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6. Develop and implement automation tools and standard engineering work processes to improve CAE modeling quality, efficiency, and repeatability.
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8. Apply optimization, DOE, and AI/ML techniques to guide battery module and pack design decisions.
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10. Partner closely with Design Release Engineers (DREs) and cross-functional teams (mechanical, electrical, systems, manufacturing) to ensure structural designs meet performance, safety, and reliability targets.
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12. Review and validate FEA models, structural calculations, and analysis reports for battery components including trays, cell tabs, BDU, ICB, side plates, and brackets.
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14. Lead root cause investigations of structural failures, test findings, and field issues, and support corrective action development.
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16. Evaluate and implement CAE software/platforms and tools (e.g., ABAQUS, HyperWorks/OptiStruct, NASTRAN, LS-DYNA, ANSA, nCode) to support analysis needs.
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18. Mentor and provide technical leadership to structural and CAE engineers across the team.
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20. Present analysis results, design recommendations, and program-level structural risk assessments to engineering and program leadership.
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22. Support continuous improvement of engineering standards, design practices, and simulation methodology.
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24. Other duties as assigned.
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Supervisory Responsibilities

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This position does not have direct reports but is expected to provide technical leadership, mentorship, and analysis review guidance to structural and CAE engineers across programs.

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Required Qualifications

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2. PhD or MS in Mechanical Engineering, Structural Engineering, Solid Mechanics, or a related technical discipline.
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4. 15+ years of experience in structural, fatigue, and durability CAE analysis, ideally within automotive, battery, or related industrial systems.
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6. Expert-level proficiency in FEA and CAE tools such as ABAQUS, HyperWorks/OptiStruct, NASTRAN, LS-DYNA, ANSA, and nCode.
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8. Strong background in fatigue, NVH, optimization/DOE, and multi-physics structural analysis.
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10. Proven track record developing CAE automation tools and standard engineering work processes.
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12. Experience with scripting/programming for CAE automation (Python, C/C++, Tcl/Tk, VBA, or similar).
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14. Demonstrated ability to define technical strategy, mentor engineers, and drive cross-functional collaboration.
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16. Excellent written and verbal communication skills, with experience presenting to engineering and program leadership.
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Preferred Qualifications

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2. PhD in Mechanical Engineering or Solid Mechanics.
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4. Direct experience with battery module/pack structural design and durability analysis.
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6. Experience applying AI/ML techniques to CAE modeling and design optimization.
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8. Experience with Teamcenter/NX or similar PLM/CAD-integration environments.
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10. Track record of patents, publications, or industry recognition in structural/CAE engineering.
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12. Design for Six Sigma or related quality/process certification.
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