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. This role involves leading the architecture, design, component selection, development, validation, and launch of lithium-ion battery packs and modules. The successful candidate will contribute to the design and development of battery systems, focusing on mechanical design, thermal management, electrical isolation, and safety-critical components.

Responsibilities

• Lead the mechanical design and development of battery modules and battery packs for material handling equipment from concept through production launch.
• Owning 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.

Benefits

• Competitive Salary
• Performance Bonus
• Generous Paid Time Off and 13 Paid Holidays
• Affordable Medical plans and no-cost Dental & Vision options
• 100% 401(k) match up to 6%
• Company-Paid Life Insurance, Short-Term Disability, and Long-Term Disability
• Tuition Assistance Program
• Employee Assistance Program (EAP) with access to mental health care, legal support, and financial guidance
• Recognition and Kaizen (continuous improvement) Reward Programs
• Meaningful opportunities for personal and professional development