Product Design Engineer - Pouch Cell Design

Lyten•San Jose, CA

About The Position

Lyten is seeking a Product Design Engineer with new process introduction and productization experience to own cell mechanical design, engineering drawings, and bills of materials for next-generation pouch battery systems. The role focuses on design for manufacturability and transition from R&D to pilot builds and scaled production, with applications in high-performance UAV platforms. The engineer will combine mechanical design expertise with battery knowledge to improve products and manufacturing processes. The position involves developing cell assembly drawings, CAD models, specifications, and BOMs; designing electrode layouts, stack architecture, and mechanical containment; and ensuring designs meet manufacturing and safety requirements. The engineer will work with cross-functional teams on performance requirements, data analysis, production-line experiments, quality controls, tolerance analysis, process improvements, and cost reduction. The role requires a bachelor’s or master’s degree in Mechanical Engineering or a related field, at least two years of mechanical design experience, CAD and PLM/PDM proficiency, and experience with data analysis and statistical process control. The work takes place in a lab and includes standing for up to eight hours per day and lifting up to 50 pounds. The position requires access to export-controlled technology and is contingent on required government authorization.

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 with cross-functional NPI or pilot builds in a fast-paced environment.
Ability to lift 50 pounds.
Ability to work in a lab while standing for up to 8 hours each day.
Eligibility for and continued availability of required government authorization to access export-controlled technology, software, and information.

Nice To Haves

At least 2 years of hands-on cell design experience.
Understanding of battery quality control methods, including Hi-Pot, 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 BOMs for pouch cell builds.
Design and optimize electrode layouts, stack architecture, and mechanical containment.
Ensure designs meet manufacturing feasibility and 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 reflect them in 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 DOEs and 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.