Design Engineer

Battery Design Engineer (High-Voltage Automotive)

Role Overview

The Battery Design Engineer will be responsible for the mechanical, structural, and thermal design of high-voltage Lithium-ion battery packs and modules for electric vehicle (EV) applications. This role requires a strong understanding of cell technology, advanced materials, manufacturing processes, and the simulation tools necessary to ensure optimal energy density, durability, and safety compliance.

Key Responsibilities

Battery Pack Design & Integration

• Lead the mechanical and structural design of the battery enclosure, modules, and sub-assemblies, ensuring requirements for sealing, weight, and volume are met.
• Specify and integrate key components, including cells, busbars, cooling plates, structural frames, and thermal interface materials (TIMs).
• Utilize SolidWorks or similar CAD systems to create 3D models and detailed 2D drawings for all battery components and the final pack assembly.

Thermal and Structural Analysis

• Conduct thermal analysis (often utilizing CFD) on battery packs to ensure adequate cooling and heating strategies for optimal cell performance and life.
• Perform structural analysis (utilizing FEA) on the battery enclosure to validate integrity under Vibration Durability, Mechanical Shock, and vehicle Crashworthiness scenarios.
• Define and manage validation testing for pack and module performance, including abuse testing and thermal cycling.

Manufacturing and Compliance

• Implement and champion Design for Manufacturing and Assembly (DFMA) principles to optimize the battery pack structure for high-volume production.
• Work closely with manufacturing teams and suppliers to resolve build issues and improve process efficiency.
• Ensure the battery pack design meets all relevant safety standards (e.g., thermal runaway, electrical isolation) and regulatory requirements (OEM and industry standards).

Collaboration & Project Management

• Collaborate with the electrical engineering team on BMS (Battery Management System) integration and high-voltage interconnects.
• Support discussions and presentations with customers, suppliers, and internal product teams throughout the development lifecycle.

Required Qualifications

• Education: Master's degree (MS/MTech) in Mechanical Engineering, Electrical Engineering, Chemical Engineering, or Materials Science.
• Experience:
• A minimum of 5-7 years of hands-on design experience with high-voltage Lithium-ion battery systems (pack/module level).
• Demonstrated proficiency in mechanical design using CAD software (e.g., SolidWorks).
• Direct experience with thermal (CFD) and structural (FEA) simulation of battery packs.