Sr Engineer, Mechanical Design – High Voltage EV Systems
Aptera Motors•Carlsbad, CA
About The Position
We are seeking an experienced Mechanical Design Engineer with expertise in packaging high-voltage systems (400 V – 800 V) for electric vehicles. This role focuses on designing compact, reliable, and safe enclosures and packaging for circuit board assemblies, busbars, harnesses, and high-voltage components. You’ll work closely with electrical and systems engineers to ensure that mechanical packaging solutions meet demanding electrical, thermal, and safety requirements.
Requirements
- Proven track record in packaging 400–800 V EV components (circuit board assemblies, busbars, harnesses, distribution units).
- Read and understand system schematics and wiring diagrams.
- Proficiency in 3D CAD tools (CATIA preferred) with ability to deliver production-ready models and drawings.
- Familiarity with EMI/EMC design considerations in packaging.
- 5+ years of experience in mechanical packaging of high-voltage systems for automotive or related industries
Nice To Haves
- Experience with Arcadia harness design tool.
Responsibilities
- Package high-voltage (400–800 V) automotive systems, including circuit board assemblies, busbars, harnesses, and power distribution units.
- Develop dense, compact layouts that optimize thermal performance, dielectric strength, clearances/creepage, and long-term reliability.
- Apply a working knowledge of dielectric properties of materials, thermal management, and material creep to ensure safe, durable designs.
- Collaborate with electrical engineers on component placement, routing, and packaging trade-offs.
- Incorporate EMI/EMC mitigation strategies into packaging solutions.
- Produce detailed 3D CAD models and 2D drawings (CATIA preferred; willingness to learn required).
- Support harness routing and packaging using Arcadia (or learn quickly on the job).
- Participate in design reviews and work closely with suppliers to ensure manufacturable solutions.
- Hands on assembly of the designs for proving out design and creating work instructions.
Benefits
- Market competitive compensation package
- Stock option grants
- Fully funded benefits package for employee + dependents
- Generous Flexible Time Away policy
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What This Job Offers
Job Type
Full-time
Career Level
Senior
