EV Battery Pack Lead Engineer

Job Title: EV Battery Pack Lead Engineer Experience: 8–15 Years

 Location: Bay Area, CA

We are looking for a highly skilled EV Battery Pack Lead Engineer to lead end-to-end design, development, validation, and industrialization of high-voltage battery packs for electric vehicles. This role requires strong technical depth in battery systems, engineering leadership, cross-functional

collaboration, and the ability to drive design decisions that meet performance, safety, cost, and timing targets.

Key Responsibilities

1.  Battery Pack Architecture & System Design

·         Lead the development of HV battery pack architecture, module configuration, cooling strategy, HV/LV distribution, and structural layout.

·         Define system requirements, technical specifications, and Interface Control Documents (ICDs).

·         Conduct trade-off studies considering cell format, thermal behavior, crash safety, cost, manufacturability, and packaging constraints.

2.  Detailed Design & Engineering Leadership

·         Guide mechanical, thermal, electrical, and BMS engineers throughout the design cycle.

·         Review CAD models, drawings, GD&T, DFMEA, and DVP&R documentation.

·         Ensure DFM/DFA best practices and compliance with industry standards (UN38.3, UL2580, ISO 26262, ISO 6469).

·         Manage supplier technical interactions for cells, cooling plates, BMS, enclosures, and busbars.

3.  CAE, Validation & Testing

·         Review CAE results (structural, crashworthiness, vibration, thermal/CFD).

·         Define and execute validation plans including DV, PV, abuse testing, IP rating, vibration, shock, and regulatory compliance.

·         Drive correlation between CAE and physical test results.

4.  Program & Stakeholder Management

·         Lead technical discussions with customers, suppliers, and cross-functional teams.

·         Manage technical risks, open issues, ECO/ECN processes, and release gates.

·         Provide status updates, review technical deliverables, and ensure timely milestone achievements.

5.  Industrialization Support

·         Support prototype builds, plant trials, PFMEA, and control plan development.

·         Coordinate with manufacturing engineering for tooling, fixtures, assembly sequence, and process validation.

·         Ensure readiness for PPAP and SOP.

Required Skills & Qualifications

·         Bachelor’s or Master’s degree in Mechanical Engineering, Electrical Engineering, Automotive Engineering, or equivalent.