Senior Mechanical Design Engineer

Clarios•United States, MI

4d•Hybrid

About The Position

Clarios is seeking a highly motivated Senior Mechanical Design Engineer to lead the mechanical design and development of advanced low-voltage and next-generation energy storage systems for automotive applications. This role is responsible for the design, development, validation, and launch of battery systems, battery management hardware packaging, power electronics enclosures, and auxiliary energy storage products from concept through production. The Senior Mechanical Design Engineer will work closely with systems engineering, electrical engineering, manufacturing, quality, purchasing, suppliers, and OEM customers to develop innovative, robust, and cost-effective solutions that meet customer, regulatory, and manufacturing requirements.

Requirements

Bachelor's degree in mechanical engineering or related engineering discipline.
Minimum 8 years of mechanical design experience.
Minimum 5 years of automotive product development experience.
Proficiency using: CATIA V5/V6, NX, Creo, or SolidWorks
Proficiency using: GD&T (ASME Y14.5)
Proficiency using: PLM systems (Teamcenter, Windchill, or equivalent)
Experience with mechanical analysis tools such as ANSYS, Abaqus, or HyperWorks.
Knowledge of automotive product development processes (APQP, PPAP, DFMEA, DV/PV testing).

Nice To Haves

Master's degree in mechanical engineering.
Experience designing battery systems, BMS packaging, power electronics enclosures, or energy storage products.
Familiarity with: Electric vehicle architectures
Familiarity with: 12V and 48V electrical systems
Familiarity with: Battery thermal management systems
Familiarity with: Functional Safety (ISO 26262)
Familiarity with: Automotive cybersecurity concepts

Responsibilities

Lead mechanical design activities for automotive battery systems, battery packs, modules, BMS enclosures, power electronics housings, and thermal management components.
Develop innovative mechanical architectures and packaging solutions for lead-acid, lithium-ion, sodium-ion, and hybrid energy storage systems.
Create and release 3D CAD models, assemblies, detailed drawings, and GD&T documentation.
Develop mechanical concepts considering performance, safety, manufacturability, serviceability, reliability, and cost targets.
Define material selections, joining methods, sealing strategies, structural designs, and enclosure architectures.
Optimize designs for weight, volume efficiency, thermal performance, durability, and manufacturability.
Perform or coordinate engineering analyses including: Structural FEA, Modal and vibration analysis, Thermal simulations, Fatigue and durability assessments, Tolerance stack-up analysis, DFMEA development.
Act as the mechanical engineering lead on customer programs.
Coordinate mechanical design activities across global engineering teams.
Support project planning, technical reviews, and milestone deliverables.
Collaborate with manufacturing engineering to ensure successful product industrialization.
Support prototype builds, pilot builds, and production launch activities.
Drive Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Serviceability (DFS) initiatives.
Support supplier technical reviews and component sourcing activities.
Interface directly with automotive OEM customers regarding requirements, design reviews, validation results, and issue resolution.
Work with suppliers to develop and qualify mechanical components and tooling.
Evaluate supplier capabilities and approve technical designs.
Identify opportunities for product cost optimization and performance improvements.
Support patent development and innovation initiatives.
Mentor junior mechanical engineers and provide technical leadership within the organization.