Product Design Engineer - Pouch Cell Design

Lyten•San Jose, CA

10d•$106,000 - $159,000

About The Position

Lyten is seeking a Product Design Engineer with new process introduction and productization experience to own mechanical design, engineering drawings, and complete bills of materials for next-generation pouch battery cells. The role focuses on design for manufacturability and transitioning products from R&D through pilot builds to scaled production, including applications for high-performance UAV platforms. The engineer will combine mechanical design expertise and battery knowledge to improve products and manufacturing processes. The position works with cross-functional partners, including technicians, operators, supply chain, and business development, to develop cell specifications, resolve assembly issues, improve processes, and establish quality controls. Responsibilities include design reviews, risk analyses, experimental work on production lines, performance data analysis, and cell and battery-pack integration activities.

Requirements

Bachelor’s or master’s degree in Mechanical Engineering or a related field.
At least 2 years of mechanical design experience.
Proficiency in CAD design; SolidWorks is preferred.
Experience with PLM/PDM systems.
Proficiency with data analysis tools such as Python, R, MATLAB, or Excel.
Knowledge of statistical process control (SPC).
Experience working on cross-functional NPI or pilot builds in a fast-paced environment.

Nice To Haves

At least 2 years of hands-on cell design experience.
Understanding of battery quality-control methods, such as Hi-Pot testing, dimensional analysis, CT scans, weld testing, and leak testing.
Strong understanding of pouch-cell architecture, cell electrochemistry, and battery-performance trade-offs.

Responsibilities

Own and develop cell assembly drawings, detailed specifications, CAD models, and bills of materials for pouch cell builds.
Design and optimize electrode layouts, stack architecture, and mechanical containment.
Ensure designs are manufacturable and meet safety requirements for NPI and pilot-build readiness.
Participate in design reviews, DFMEA/PFMEA, and engineering change documentation.
Identify and resolve pouch-cell assembly issues, including tab alignment, sealing integrity, and electrolyte distribution.
Understand pilot-line process capabilities and incorporate them into cell design.
Develop battery performance specifications based on business development needs and customer requirements.
Use statistical analysis tools to identify trends and correlations in battery performance data.
Partner with technicians and operators to identify and implement process improvements.
Design and execute production-line Design of Experiments (DOEs), with follow-through on MES systems.
Lead tolerance stack-up analysis for battery-pack assemblies and cell integration.
Establish and validate in-process quality-control methods and inspection criteria.
Work with the supply chain team on cost-reduction initiatives and value engineering.