Design Engineer, Battery Systems

Design Engineer

We are seeking a hands-on Design Engineer to focus on the development and optimization of flexible interconnects and battery connection systems for high-performance EV and energy storage applications. The Design Engineer will have a strong background in battery pack architecture, cell connection methods, and electromechanical system integration, particularly involving Li-ion cell technologies.

Essential Duties and Responsibilities

• Design and develop battery interconnects, current collector assemblies, voltage sense harnesses, and other power distribution elements.

• Create and maintain detailed 3D CAD models and 2D engineering drawings for PCBA and flexible interconnect designs, using GD&T principles and an understanding of stackup analysis to define dimensions.

• Translate internal system-level performance and regulatory requirements into detailed product-level specifications.

• Perform hands-on prototyping and support the transition from early design into pilot and production phases.

• Lead design reviews and support Design for Manufacturability (DFM) and Design for Assembly (DFA) analysis.

• Define and execute validation plans (DVP&R), DFMEA, and other APQP deliverables.

• Evaluate and recommend materials and stack-ups to optimize mechanical, thermal, and electrical performance.

• Size busbars and interconnects using simulation and analytical methods (e.g., Joule heating calculations).

• Collaborate with cross-functional engineering teams to support pack integration and production scalability.

Minimum Qualifications (Knowledge, Skills and Abilities)

To perform this job successfully, the individual must perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions.

• A minimum of 2-4 years of extensive experience and deep knowledge of electrical systems in one or more of the following industries: aerospace, robotics, data centers, medical, appliances, or similar.

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or a related engineering field.

• Solid understanding of Li-ion battery cells (pouch, prismatic, cylindrical), their behavior, and integration challenges and needs.

• Experience with battery pack design, including voltage/current balancing, series-parallel configuration, and energy density optimization.

• Proficient with CAD tools (e.g., SolidWorks, NX, or similar) for mechanical design and drafting.

• Knowledge of cell connection manufacturing techniques such as laser welding, ultrasonic welding, and resistance welding.

• Familiarity with electrical joint design, mechanical fastening, and insulation strategies for battery systems.

• Understand requirements of part condition at End of Line (Hi Pot Testing, Continuity Testing, Resistance Testing, Weld Integrity) be able to communicate requirements in drawings and provide cross-functional teams with necessary information to execute low volume and prototype tooling, fixtures, etc.

• Comfortable working with and interpreting material data for conductors, insulators, adhesives, and coatings.

• Strong hands-on skills for prototyping, testing, and troubleshooting.

• Familiarity with flex circuit manufacturing and related materials and processes is preferred.

• Experience with automotive or energy storage design validation protocols and reliability testing preferred.

Base Salary: Starting at 80k+. We’re hiring for multiple positions/levels and will align compensation accordingly.

Physical Demands and Work Environment

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform the functions.

Working Conditions/Hours

Salaried Exempt

Physical Demands – Office and Manufacturing Environment

While performing the duties of this position, the employee is regularly required to talk or hear. The employee frequently is required to use hands or fingers, handle, or feel objects, tools, or controls. The employee is required to stand, walk; sit; reach with hands and arms pull/push; climb or balance; and stoop, kneel, crouch, or crawl. The employee must lift and/or move up to 50 pounds without assistance. Specific vision abilities required by this position include close vision, distance vision, color vision, peripheral vision, and the ability to adjust focus.

Work Environment –

Includes both a typical office environment, with minimal exposure to excessive noise or adverse environmental issues, and a shop environment, with exposure to high noise levels from operating machines, physical hazards from moving equipment and machine parts, nuisance dust, and skin exposure to chemicals used to run/maintain machines.

PPE-

May be required to wear Personal Protective Equipment, including but not limited to safety glasses, safety shoes, bump caps, gloves, hair nets, masks, & clean-room frocks while adhering to the prescribed safety procedures.

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