Battery Pack Design Engineer

About the role

We’re seeking a passionate and dedicated Battery Pack Design Engineer who brings enthusiasm and expertise to the table. In this role, you’ll lead the architecture, design, component selection, development, validation, and launch of lithium-ion battery packs and modules. This role will play a key part in the design and development of battery systems, contributing to battery structures, module packaging, thermal management systems, electrical isolation features, safety-critical components, and enclosure assemblies from concept through production release.

Responsibilities

• Lead the mechanical design and development of battery modules and battery packs for material handling equipment from concept through production launch.
• Own battery module and pack architectures such as structural components, cell retention systems, compression mechanisms, cooling systems, electrical isolation features, busbar integration, and serviceable assemblies.
• Create and release production-ready CAD models, engineering drawings, specifications, and BOMs.
• Perform packaging studies and trade-off analyses for battery cells, modules, cooling systems, safety-critical components, and supporting structures.
• Drive Design for Manufacturing (DFM), Design for Assembly (DFA), and serviceability initiatives throughout the product development cycle.
• Collaborate with electrical, BMS, systems, and thermal engineering teams to ensure successful integration of mechanical and electrical subsystems.
• Support structural, thermal, vibration, shock, abuse, and environmental validation activities.
• Develop and maintain DFMEAs, DVP&Rs, Engineering Specifications, Statements of Work, and supplier technical requirements.
• Lead engineering prototype builds, design verification activities, root cause investigations, and corrective action implementation.
• Conduct tolerance stack-up analyses and apply GD&T best practices to ensure robust production designs.
• Work directly with suppliers on component development, tooling feasibility, APQP activities, and production readiness reviews.
• Support battery pack safety strategies including thermal runaway mitigation, electrical isolation, ingress protection, and compliance requirements.
• Identify technical risks early and develop mitigation plans to ensure successful program execution.
• Support manufacturing launch activities and transition designs into volume production environments.

Requirements

• Bachelor’s degree in Mechanical Engineering or related engineering discipline.
• 10+ years of product development experience with demonstrated success launching complex electromechanical systems into production.
• 5+ years of direct experience designing lithium-ion battery modules, battery packs, or high-voltage energy storage systems.
• Strong understanding of battery cell technologies, module architectures, pack integration, and energy storage system design.
• CAD proficiency using Creo, CATIA, NX, or equivalent 3D modeling software.
• Strong knowledge of GD&T, tolerance analysis, and engineering drawing standards.
• Familiarity with manufacturing processes including castings, stampings, extrusions, sheet metal, plastics, machining, and assembly operations.
• Experience supporting prototype builds, validation testing, production launches, and supplier development activities.
• Working knowledge of CAE tools supporting thermal, structural, vibration, and durability analysis.
• Experience developing DVP&R, DFMEA, PFMEA, Engineering Specifications, and APQP deliverables.
• Strong technical communication and cross-functional leadership skills.
• Able to work effectively in fast-paced product development environments.

Qualifications

• Direct ownership of battery module or battery pack designs that successfully launched into production.
• Experience with cylindrical, prismatic, or pouch cell packaging architectures.
• Expertise in battery cooling systems including liquid, refrigerant, or air-cooled designs.
• Experience with cell compression systems, busbar integration, HV interconnects, and electrical isolation strategies.
• Knowledge of battery abuse testing, thermal runaway containment, propagation mitigation, and safety design principles.
• Experience developing systems compliant with UL, IEC, SAE, ISO, and UN38.3 requirements.
• Familiarity with battery manufacturing processes, module assembly lines, and pack production systems.
• Hands-on prototype build experience and comfort working directly with hardware in the lab and on the manufacturing floor.
• Experience supporting innovation and advanced concept development.