Senior Product Development Engineer

Location: Ann Arbor, Michigan

Department: Product Engineering

Reports To: Director of Product Engineering

Employment Type: Full-Time

About EGI Battery

EGI Battery is a U.S.-based manufacturer of advanced lithium-ion batteries, focused on delivering NDAA-compliant energy solutions for critical applications. Headquartered in Ann Arbor, Michigan, EGI is building a secure, domestic supply chain to support the growing demand for high-performance batteries in drone, eVTOL, and energy storage markets.

Position Summary

EGI Battery is seeking a highly motivated and technically versatile Senior Product Development Engineer to support the development, industrialization, and launch of advanced lithium-ion battery products. This role serves as a key technical resource bridging Product Engineering, Design Release Engineering (DRE), and Process Engineering functions throughout the product lifecycle. The successful candidate will lead activities from early-stage research and development through prototype and pilot production while ensuring a successful transition into full-scale manufacturing.

The ideal candidate will possess a broad engineering background with experience in product design, manufacturing processes, technical documentation, and production launch activities. Working closely with R&D, Manufacturing, Quality, Supply Chain, Equipment Engineering, and external suppliers, this individual will help ensure products meet performance, quality, reliability, manufacturability, and cost objectives.

Essential Duties and Responsibilities:

Product Development

· Support the development of lithium-ion battery products from concept through production launch.

· Collaborate with R&D teams to transform concepts into manufacturable products.

· Develop and maintain product specifications, engineering requirements, and technical documentation.

· Evaluate product performance, reliability, safety, and manufacturability during all phases of development.

· Support prototype builds, engineering trials, pilot production activities, and validation testing.

· Conduct technical analysis, root cause investigations, and corrective action implementation.

· Participate in product design reviews and cross-functional engineering reviews.

· Support customer, supplier, and internal technical discussions as required.

Design Release Engineering (DRE)

· Create, release, and maintain engineering drawings, specifications, bills of material (BOMs), and related documentation.

· Manage product configurations and engineering change control processes.

· Lead Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs).

· Ensure designs meet functional, manufacturing, quality, safety, and cost requirements.

· Coordinate design reviews and approval processes.

· Maintain document control and product traceability throughout the product lifecycle.

· Support implementation and maintenance of PLM and document management systems.

Process Engineering

· Develop and optimize manufacturing processes for battery products and assemblies.

· Support process development activities from laboratory and prototype environments through pilot manufacturing.

· Collaborate with equipment suppliers and manufacturing personnel to establish robust production processes.

· Develop process flow diagrams, manufacturing procedures, work instructions, control plans, and related documentation.

· Improve manufacturing safety, quality, yield, throughput, and cost performance.

· Lead troubleshooting and resolution of process-related manufacturing issues.

· Support process validation, capability studies, and continuous improvement initiatives.

· Assist in the specification, installation, qualification, and startup of manufacturing equipment.

New Product Introduction (NPI) and Production Launch

· Act as the primary technical liaison between R&D and Manufacturing.

· Assist with Design for Manufacturability (DFM) and Design for Assembly (DFA) reviews.

· Plan and coordinate prototype, engineering, pilot, and pre-production builds.

· Establish manufacturing readiness criteria and product launch plans.

· Support production ramp-up and transfer of products into manufacturing operations.

· Drive closure of launch-related technical issues.

· Ensure successful handoff of products and processes from development to production teams.

· Provide ongoing technical support during early production phases.

Required Qualifications

· Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, Chemical Engineering, Electrical Engineering, Materials Engineering, or a related engineering discipline.

· Minimum ten (10) years of experience in product engineering, manufacturing engineering, process engineering, battery manufacturing, automotive, electronics, or related industries.

· Experience developing and maintaining engineering drawings, specifications, and bills of material.

· Experience supporting new product development and manufacturing launch activities.

· Strong understanding of manufacturing processes and engineering change management.

· Demonstrated problem-solving and root cause analysis skills.

· Excellent written and verbal communication skills.

· Ability to effectively manage multiple projects and priorities in a fast-paced environment.

· Strong organizational and cross-functional collaboration skills.

Preferred Qualifications

· Experience with lithium-ion battery manufacturing.

· Knowledge of APQP, PPAP, FMEA, Control Plans, SPC, and MSA methodologies.

· Experience supporting prototype, pilot, and production manufacturing operations.

· Experience using CAD software such as SolidWorks, AutoCAD, CATIA, or similar platforms.

· Experience using PLM, ERP, and document control systems.

· Lean Manufacturing and/or Six Sigma certification a plus.

Knowledge, Skills, and Competencies

· Product Development

· Design Release Engineering

· Manufacturing Process Development

· Configuration Management

· Engineering Documentation and Change Control

· Design for Manufacturability (DFM)

· Design for Assembly (DFA)

· Root Cause Analysis

· Project Management

· Continuous Improvement

· New Product Introduction (NPI)

· Cross-Functional Leadership

· Technical Communication

· Battery Manufacturing Processes

Success in this role will be demonstrated through:

· Successful development and launch of new battery products.

· Timely release and maintenance of engineering documentation and product definitions.

· Development of manufacturing processes capable of meeting safety, quality, throughput, and cost targets.

· Effective transfer of products from R&D through pilot production and into full-scale manufacturing.

· Improvements in product quality, manufacturing yield, and operational efficiency.

· Strong collaboration across engineering, manufacturing, quality, and supply chain functions.

Compensation

· The base salary range for this position will be determined based on the candidate’s experience, qualifications, skills, and other relevant factors.

· 100% 401(k) match up to 5% of base salary

· Medical, dental, and vision insurance through BCBS.

· This position is eligible for performance-based bonus and/or equity incentive plans in accordance with EGI Battery’s applicable programs.

Physical Demands

· Ability to work primarily from EGI’s Ann Arbor location and collaborate in office, laboratory, and manufacturing environments.

· Ability to travel domestically and internationally, as needed, for customer, supplier, equipment, facility, and program engagements.

· Ability to enter manufacturing and laboratory areas and comply with applicable safety and personal protective equipment requirements.

Work Authorization and Visa Sponsorship

· Applicants must be currently authorized to work in the United States.

· EGI Battery does not provide employment-based visa sponsorship for this position at this current time.