Senior Mechanical Engineer, Pack Design

Our Next Energy•Novi, MI

13d

About The Position

This role is responsible for the design and engineering of battery pack mechanical components or sub-systems, from the initial concept phase through to product launch. The engineer will develop innovative mechanical solutions that effectively balance performance, manufacturability, cost, quality, weight, thermal performance, and project timelines. A key aspect of the role involves close collaboration with various teams, including BMS, systems, electrical, thermal, manufacturing, validation, and quality, to ensure all design requirements are met. The position also requires ensuring proper electrical isolation and environmental protection are integrated into the designs. The engineer will utilize CAD software to create and maintain 3D models and detailed 2D engineering drawings with GD&T, and conduct tolerance stack analyses to ensure component fit, function, and assembly robustness. Hands-on support for prototype builds, troubleshooting, and issue resolution is expected, along with early identification and mitigation of technical risks through rapid prototyping. Collaboration with suppliers on design for manufacturability (DFM), sourcing, tooling feasibility, and component quality is crucial, including potential travel to supplier locations. The role also involves interpreting and applying analysis results (structural, thermal) to optimize designs, supporting testing and validation activities, and contributing to intellectual property development. Participation in engineering and design reviews, APQP activities, and continuous improvement initiatives is also part of the responsibilities, culminating in support for successful prototype, pilot, and production launches. Additional duties may be assigned to support business and product development objectives.

Requirements

Bachelor’s degree in Mechanical Engineering or related engineering discipline required
Minimum 2+ years of mechanical engineering experience for Engineer level; 5+ years preferred for Senior level
Experience designing mechanical components and sub-systems in automotive, EV battery, or advanced manufacturing applications preferred
Experience with 3D CAD software such as OnShape, CATIA, NX, Creo, or SolidWorks
Working knowledge of GD&T and engineering drawing standards
Experience supporting product development from concept through production launch
Understanding of manufacturing processes including castings, stampings, extrusions, plastics, machining, and assemblies
Strong problem-solving and analytical skills
Excellent written and verbal communication skills
Ability to work effectively in a fast-paced and highly collaborative environment

Nice To Haves

Master’s degree in Mechanical Engineering or related discipline
Experience with battery pack or high-voltage system design
Hands-on prototype build and launch experience
Experience working directly with suppliers on DFM and component validation
Familiarity with structural and thermal analysis interpretation
Experience designing for vibration, thermal cycling, water intrusion, and corrosion environments
Knowledge of automotive product development processes and APQP methodologies
Formula SAE, EcoCAR, or similar collegiate engineering project experience considered applicable

Responsibilities

Own the design and engineering of one or more battery pack mechanical components or sub-systems from concept through product launch
Develop innovative mechanical solutions balancing performance, manufacturability, cost, quality, weight, thermal performance, and timing
Interface closely with BMS, systems, electrical, thermal, manufacturing, validation, and quality teams to ensure all component and sub-system requirements are achieved
Ensure proper electrical isolation and environmental protection requirements are incorporated into designs
Create and maintain 3D CAD models and detailed 2D engineering drawings with GD&T using OnShape or equivalent CAD software
Conduct tolerance stack analyses to validate component fit, function, and assembly robustness
Support prototype builds and hands-on development activities including troubleshooting, fit-up, and issue resolution
Identify technical risks early and rapidly prototype solutions to validate concepts and mitigate issues
Collaborate with suppliers on design for manufacturability (DFM), sourcing, tooling feasibility, and component quality
Travel to supplier locations as necessary to evaluate capabilities, review tooling/process readiness, and support launch activities
Interpret and apply structural, thermal, and mechanical analysis results to improve designs and optimize performance
Support testing, validation, root cause analysis, and corrective action implementation
Contribute to intellectual property development including invention disclosures and patent support activities
Participate in engineering reviews, design reviews, APQP activities, and continuous improvement initiatives
Support successful prototype, pilot, and production launches
Perform additional duties as assigned to support business and product development objectives