Senior Mechanical Engineer, Pack Design

Essential Duties and Responsibilities:

• Own the design and engineering of one or more battery pack mechanical components or sub-systems from concept through product launch
• Develop innovative mechanical solutions balancing performance, manufacturability, cost, quality, weight, thermal performance, and timing
• Interface closely with BMS, systems, electrical, thermal, manufacturing, validation, and quality teams to ensure all component and sub-system requirements are achieved
• Ensure proper electrical isolation and environmental protection requirements are incorporated into designs
• Create and maintain 3D CAD models and detailed 2D engineering drawings with GD&T using OnShape or equivalent CAD software
• Conduct tolerance stack analyses to validate component fit, function, and assembly robustness
• Support prototype builds and hands-on development activities including troubleshooting, fit-up, and issue resolution
• Identify technical risks early and rapidly prototype solutions to validate concepts and mitigate issues
• Collaborate with suppliers on design for manufacturability (DFM), sourcing, tooling feasibility, and component quality
• Travel to supplier locations as necessary to evaluate capabilities, review tooling/process readiness, and support launch activities
• Interpret and apply structural, thermal, and mechanical analysis results to improve designs and optimize performance
• Support testing, validation, root cause analysis, and corrective action implementation
• Contribute to intellectual property development including invention disclosures and patent support activities
• Participate in engineering reviews, design reviews, APQP activities, and continuous improvement initiatives
• Support successful prototype, pilot, and production launches
• Perform additional duties as assigned to support business and product development objectives

Required Qualifications:

• Bachelor's degree in Mechanical Engineering or related engineering discipline required
• Minimum 2+ years of mechanical engineering experience for Engineer level; 5+ years preferred for Senior level
• Experience designing mechanical components and sub-systems in automotive, EV battery, or advanced manufacturing applications preferred
• Experience with 3D CAD software such as OnShape, CATIA, NX, Creo, or SolidWorks
• Working knowledge of GD&T and engineering drawing standards
• Experience supporting product development from concept through production launch
• Understanding of manufacturing processes including castings, stampings, extrusions, plastics, machining, and assemblies
• Strong problem-solving and analytical skills
• Excellent written and verbal communication skills
• Ability to work effectively in a fast-paced and highly collaborative environment

Preferred Qualifications:

• Master's degree in Mechanical Engineering or related discipline
• Experience with battery pack or high-voltage system design
• Hands-on prototype build and launch experience
• Experience working directly with suppliers on DFM and component validation
• Familiarity with structural and thermal analysis interpretation
• Experience designing for vibration, thermal cycling, water intrusion, and corrosion environments
• Knowledge of automotive product development processes and APQP methodologies
• Formula SAE, EcoCAR, or similar collegiate engineering project experience considered applicable