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 CFT with necessary information to execute touch 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.