Sr. Battery Engineer

Responsibilities

• Drive sustaining engineering for in-production HV battery systems
• Serve as a technical expert for HV battery packs in series production, with primary focus on field performance, reliability, and serviceability
• Act as a key liaison between Service, Reliability, Reman, FAME, Plant ME/PE/Ops, Supplier Quality, and Product Development to drive durable solutions to battery issues observed in the field and at service centers
• Maintain a system-level view of how hardware, BMS software, diagnostics, and vehicle usage patterns interact to impact customer experience
• Own field performance analyses and service issue mitigation
• Analyze field, warranty, and ongoing reliability test data to detect trends, characterize emerging failure modes, and quantify risk to customers and the business
• Lead root cause investigations for HV battery-related field and service issues (e.g., no-start, reduced performance, diagnostic trouble codes, degradation anomalies), driving permanent corrective and preventive actions
• Partner closely with Service Engineering and Technical Support to define, refine, and validate diagnostic strategies, service procedures, and repair paths, ensuring they are robust, efficient, and safe for field execution
• Support prioritization and validation of field actions (e.g., service campaigns, software updates, component changes) and clearly communicate risk/benefit trade-offs to cross-functional stakeholders
• Drive DFM, serviceability, and remanufacturing improvements
• Provide lessons learned and DFM feedback from field and production back into battery architecture, component selection, and integration strategies for current and future programs
• Collaborate with Manufacturing Engineering, Reman, and Supplier Quality to improve build robustness, yield, rework/repair strategies, and remanufacturing flows for HV battery assemblies
• Influence design decisions to improve service access, diagnostic coverage, component modularity, and repairability, minimizing customer downtime and total cost of ownership
• Contribute to new product and system strategy
• Partner with the new product design teams to ensure that issues observed on current products inform requirements, architecture, and test strategies for upcoming battery platforms
• Work with design teams to update part models and drawings as part of corrective action cycles for field failures and reliability issues
• Support the development and maturation of cross-functional processes (PD, ME, Ops, Service, Reliability, Reman) that tie together design, manufacturing, and field data to accelerate problem detection and resolution
• Elevate technical rigor and cross-functional communication
• Analyze test and field data, author clear technical reports, and present findings and recommendations to engineering leadership and cross-functional partners
• Create and maintain system-level documentation (e.g., requirements, DFMEAs inputs, fault trees, test plans/summary reports) that connect observed issues back to design and process controls
• Aid other engineers in structured problem solving, data-driven decision making, and best practices in battery sustaining engineering.

Qualifications

• 3+ years of experience in Battery, Automotive, Aerospace, or related industries, with significant exposure to HV battery systems, field performance, or failure analysis
• A bachelor’s degree in an engineering discipline (e.g., Electrical, Mechanical, Mechatronics, Automotive, or related)
• An advanced degree is a plus
• Previous experience with product launches, production schedules, and release engineering (including CAD design, GD&T, and PLM interface)
• Mechanical engineering experience required, electronics / controls experience a plus
• Passion for working on products that involve the intersection of mechanical, electrical, and software engineering
• Strong understanding of HV battery system architecture, including cells, modules, pack, contactors, pyros, sensing, cooling, BMS hardware/software, and vehicle interfaces
• Demonstrated experience with field issue root cause analysis, including use of telematics, warranty, and diagnostic data to drive corrective and preventive actions
• Working knowledge of battery diagnostics and prognostics, including DTC strategies, state-of-charge/health estimation, imbalance detection, and fault handling
• Familiarity with DFM/DFS/DFR principles, production test strategies (e.g., End-of-Line), and their relationship to field performance and reliability
• Solid understanding of high-voltage safety and safe work practices in both lab and field environments
• Proficiency using CAN/Ethernet tools for debugging purposes a plus
• Background with CATIA V6 (3Dx) CAD Design and Enovia a plus
• Excellent problem-solving skills, grounded in core engineering principles, first-principles reasoning, and structured root cause methodologies
• Proven ability to work in a fast-paced environment with a strong sense of ownership, urgency, and follow-through from problem identification to implemented solution
• Experience working in cross-functional teams, with the ability to bridge design, manufacturing, service, and reliability perspectives
• Strong verbal and written communication skills, including the ability to simplify complex technical topics for diverse audiences
• Familiarity with issue tracking and project management tools (e.g., Jira, etc.)