Battery Pack Mechanical Design Engineer II, Amazon Prime Air - Electric Propulsion Subsystem

About the Role

We are seeking a Battery Pack Mechanical Hardware Development Engineer II to join our Drone Electric Propulsion Subsystem (EPS) team. In this role, you will be a significant and autonomous contributor, solving difficult hardware engineering problems related to battery systems. You will design, develop, and validate battery packs from concept through production, working on high-voltage battery systems that push the boundaries of performance, reliability, efficiency, and safety.

Responsibilities

• Design mechanical architecture for high-voltage Li-Ion battery packs, including cell arrangement, modules, enclosures, structural supports, and interconnections.
• Create detailed 3D models and manufacturing drawings using CATIA with GD&T.
• Develop cell-to-module and module-to-pack packaging concepts balancing energy density, safety, and manufacturability.
• Design and integrate thermal management systems and sealed, IP-rated enclosures.
• Perform FEA (structural, vibration, thermal) and tolerance stack-up analysis to validate designs.
• Plan and execute prototype builds, validation testing, and root-cause failure analysis.
• Design to high-voltage safety requirements including creepage/clearance, isolation, and HVIL.
• Incorporate thermal runaway mitigation and ensure compliance with applicable standards (UN 38.3, UL 2580, IEC 62133, etc.).
• Develop verification test plans to verify designs against DO-160 and DO-274 standards.
• Support DFMEA and design-for-safety activities.
• Partner with electrical, BMS, systems, and safety engineers on mechanical and interface requirements.
• Coordinate with manufacturing, supply chain, and suppliers on DFM/DFA, tooling, and sourcing.
• Participate in and present at design reviews.
• Maintain engineering documentation and manage changes through PLM.
• Support project planning with estimates, timelines, and risk assessments.
• Identify opportunities to improve cost, weight, safety, and manufacturability.
• Contribute to team design standards and best practices.

Requirements

• Bachelor's degree in mechanical engineering or equivalent.
• 4+ years of working in mechanical engineering or equivalent experience.
• Demonstrated experience taking a mechanical design from concept through prototype to production.
• Battery pack mechanical design experience: cell-to-pack architecture, module design, cell holders, busbar integration, enclosures, and structural support for prismatic, cylindrical, or pouch cells.
• CAD proficiency: SolidWorks, Creo, CATIA, or NX for 3D modeling, GD&T, and detailed drawings.
• Sealing and enclosure design experience: IP-rated enclosures, gaskets, potting/encapsulation, and pressure equalization/venting.
• Understanding of high-voltage safety practices, creepage and clearance requirements, and isolation/insulation coordination.
• Familiarity with thermal runaway mitigation and propagation prevention (venting, barriers, intumescent materials).
• Interface knowledge with BMS, contactors, fuses, HVIL, and service disconnects.
• Awareness of cell chemistry behavior and its impact on mechanical/thermal requirements.
• Experience with DFM/DFA and joining methods (laser/ultrasonic/resistance welding, adhesives, fastening).
• Tolerance analysis and supplier collaboration on tooling, injection molding, sheet metal, die casting, or extrusions.
• Prototyping, bring-up, and validation testing experience (environmental chambers, vibration tables, HALT/HASS).
• DFMEA and design-for-safety methodology knowledge.
• Familiarity with PLM systems and engineering change management.
• Strong collaboration skills with cross-functional teams.
• Experience with requirements definition, design reviews, and technical documentation.
• Root-cause analysis and structured problem-solving skills (8D, DMAIC, fishbone).

Qualifications

• Master's degree in mechanical engineering or equivalent (preferred).
• 3+ years of working in mechanical engineering or equivalent experience (preferred).
• Thermal management experience: cooling systems (liquid cold plates, air cooling, phase-change or immersion), thermal interface materials, and heat management.
• Structural/mechanical analysis experience: FEA for stress, vibration, shock, and drop; tolerance stack-up analysis.
• Experience in automotive, aerospace, marine, or grid-storage battery systems.
• Scripting/simulation tools experience (MATLAB, Python) for design automation or thermal modeling.
• Experience with fast-charge thermal design and high-C-rate applications.

Pay

The base salary range for this position in Seattle, WA, USA is $117,300.00 - $160,000.00 annually. Final compensation will be determined based on factors including experience, qualifications, and location. The Amazon package includes sign-on payments and restricted stock units (RSUs).

Benefits

Amazon offers comprehensive benefits including health insurance (medical, dental, vision, prescription), Basic Life & AD&D insurance, EAP, Mental Health Support, 401(k) matching, paid time off, and parental leave.

Amazon is an equal opportunity employer and does not discriminate on the basis of protected veteran status, disability, or other legally protected status. Our inclusive culture empowers Amazonians to deliver the best results for our customers.