Mechanical Design Engineer - Battery Systems

About the role

Join a forward-thinking engineering team pioneering the next generation of lightweight battery systems for consumer electronics and advanced robotics. As a Mechanical Design Engineer, you will architect and validate robust, scalable batteries that are integral to enabling reliable, high-performance battery use cases. Your technical leadership will drive innovation in safety, mechanical integration, and cross-disciplinary collaboration for demanding real-world applications.

Responsibilities

• Architect, engineer, and optimize lightweight, swappable battery systems with emphasis on safety, weight reduction, and reliability for robotic applications.
• Lead design, validation, performance, endurance, and life cycle testing of battery subsystems, overseeing testing methodologies and data analysis.
• Diagnose and resolve mechanical issues through failure analysis, root-cause investigations, design iteration, and empirical validation.
• Guide contract manufacturers (CMs) and scaling partners in preparation for high-volume production transitions, ensuring manufacturability and quality.
• Work closely with reliability, electrical, and firmware engineers to implement best practices for high-reliability mechanical and electrical integration.
• Develop custom test fixtures, write test protocols, execute tests, and analyze measurement data to inform continuous design improvements.
• Design battery docking and interface components; support the development of ancillary robotic subsystems as needed.
• Oversee prototyping using diverse manufacturing processes and material choices suitable for battery and electronics enclosures.
• Execute tolerance analysis, GD&T application, and perform static structural and modal FEA simulations to validate mechanical robustness.

Minimum Qualifications

• 8+ years of mechanical design engineering experience, focused on complex electromechanical systems.
• Bachelor’s degree (or equivalent practical experience) in Mechanical Engineering or a related technical field.
• Demonstrated expertise developing lightweight, custom battery modules and mechanical packaging for electrical systems.
• Strong background in battery and electronics thermal management strategies.
• Hands-on with design-of-experiments (DOE) and execution of performance and validation test protocols.
• Proficient in advanced CAD tools such as SOLIDWORKS, Siemens NX, or similar platforms, and capable with manufacturing prototyping.
• Expertise in tolerance analysis and application of GD&T per industry standards.
• Skilled in finite element analysis (FEA) including both static structural and modal evaluations.
• Proven track record managing engineering projects under fast-paced, ambiguous, or evolving priorities.

Preferred Qualifications

• Experience developing robotics and/or consumer electronics products in high-performance, cross-functional teams.
• Demonstrated ability to lead projects from concept through full-scale deployment in demanding environments.
• Proven skill in using AI tools to enhance mechanical engineering workflows, improve efficiency, or elevate design quality.
• Evidence of ongoing engagement with AI-driven methodologies (e.g., prompt engineering, agent orchestration) or a commitment to staying current with emerging technologies.

Pay

CA Base Pay: $170,000 USD – $225,000 USD

Benefits

• Premium PPO and HMO medical insurance
• Dental and vision coverage
• Flexible spending accounts (FSA)
• Life insurance
• Short- and long-term disability insurance
• Company-matched 401(k) plan
• Generous paid time off policy