Mechanical Design Engineer- R & D

Mechanical Design Engineer / Lead Mechanical Design Engineer

Job Summary

We are seeking an experienced Mechanical Design Engineer / Lead Mechanical Design Engineer with strong expertise in Battery Energy Storage Systems (BESS), Commercial & Industrial (C&I) battery systems, and EV battery systems. The role will lead mechanical product development from concept, detailed design, prototyping and validation through production, ensuring robust, safe, cost-effective, and manufacturable designs.

Key Responsibilities

Mechanical Design & Product Development

• Design and develop mechanical systems, enclosures, frames, racks, battery modules/packs, mounting systems, brackets, busbar supports, and cooling-system interfaces.
• Lead product development from concept through detailed engineering, prototyping, validation, and production.
• Create and review 3D CAD models, 2D manufacturing/assembly drawings, BOMs, specifications, and engineering documentation.
• Ensure designs meet requirements for strength, stiffness, thermal management, safety, reliability, serviceability, DFM, and DFA.

Structural Analysis & Validation

• Perform/coordinate FEA and structural analysis using tools such as ANSYS, Abaqus, HyperWorks, or equivalent.
• Evaluate static, seismic, vibration, shock, transportation/handling, mounting, installation, and thermal expansion loads.
• Interpret simulation results, drive design improvements, and support prototype testing and simulation-to-test correlation.

Engineering & Manufacturing

• Develop and maintain BOMs, part/assembly drawings, product configurations, prototype documentation, and engineering change documentation.
• Ensure drawings comply with applicable standards, GD&T, tolerancing, and internal engineering processes.
• Work closely with Manufacturing and Supply Chain teams on materials, fabrication methods, supplier capabilities, and production readiness.

Cross-Functional Collaboration

• Collaborate with Electrical, BMS, HVAC/Thermal, Safety, Manufacturing, Quality, and Supply Chain teams.
• Resolve mechanical/electrical/thermal interface issues and lead design, technical, and validation reviews.

Team Leadership & Cost Optimization

• Lead and mentor mechanical engineering teams, allocate activities, review designs and analysis, and ensure timely project delivery.
• Identify technical risks and drive mitigation plans.
• Optimize designs for cost, weight, manufacturability, assembly, serviceability, and scalability.

Key Deliverables

• 3D CAD models and 2D manufacturing/assembly drawings
• Detailed BOMs and product configuration documentation
• Prototype and production documentation
• FEA/structural analysis and validation reports
• Design review presentations and engineering change documentation
• Production-ready mechanical designs

Required Qualifications

• Bachelor's/Master's degree in Mechanical, Mechatronics, Automotive Engineering, or related discipline.
• 712+ years of relevant mechanical product design/development experience.
• Strong experience in BESS, EV batteries, energy storage, automotive, or high-performance battery systems preferred.
• Proficiency in SolidWorks, Creo, CATIA, NX, or equivalent 3D CAD tools.
• Experience with FEA/structural analysis tools such as ANSYS, Abaqus, or HyperWorks.
• Strong knowledge of mechanical design, materials, manufacturing processes, GD&T, tolerancing, and DFM/DFA.
• Proven experience taking products from prototype through validation and production.
• Experience leading or mentoring mechanical engineering teams.

Preferred Technical Experience

• Hands-on experience with containerized BESS, C&I battery systems, or EV battery packs/modules.
• Knowledge of battery pack/module mechanical architecture, thermal management, cooling interfaces, safety, and structural requirements.
• Experience with product cost optimization, supplier development, and production scale-up.