Senior Mechanical Engineer, Battery

Overview

WORK LOCATION:

Ann Arbor, MI

FLSA STATUS:
Exempt

Salary range:
The anticipated salary range for this role is $105,000 to $135,000 annually. This range reflects a good faith estimate based on the targeted level for the role and typical compensation benchmarks across U.S. locations. Actual compensation may vary depending on the selected candidate’s qualifications, experience, geographical location, and internal alignment.

SUMMARY

The Senior Mechanical Engineer is responsible for leading the design, development, and validation of complex mechanical systems and subsystems for Lithium Battery power systems used in uncrewed aerial systems (UAS). This role demonstrates a strong blend of technical depth, design execution, and leadership capability. The engineer independently owns major subsystem designs—balancing performance, reliability, and manufacturability—and contributes to the broader engineering architecture through technical review and mentorship.

The Senior Engineer provides hands-on leadership during prototype builds, test campaigns, and production transitions. They are recognized for their expertise in mechanical design and cross-functional coordination, driving technical excellence and contributing to design standards and process improvements across multiple programs.

The Senior Engineer is expected to provide hands-on leadership during prototype builds, test campaigns, and production transitions.

• Lead the design, modeling, and analysis of major mechanical and structural subsystems for Battery power systems and their supporting products.
• Perform and review tolerance analysis, structural analysis (FEA), and materials selection.
• Oversee battery mechanical design to meet performance and safety requirements.
• Manage design documentation, drawing release, and configuration management activities.
• Coordinate design integration across disciplines—mechanical, electrical, and software.
• Guide prototype builds, resolving issues related to manufacturability, fit, and performance.
• Develop and execute test plans to validate structural integrity and system performance.
• Lead and participate in design reviews (CoDR, PDR, CDR) and incorporate feedback into designs.
• Support production readiness and quality verification for new and existing products.
• Mentor junior engineers and CAD specialists, promoting technical best practices and efficient workflows.
• Contribute to continuous improvement initiatives in design standards, configuration management, and documentation processes.

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field required.
• 4–7 years of relevant experience in mechanical or aerospace engineering, with demonstrated ownership of major subsystems or assemblies.
• Experience with lithium battery design, packaging, and safety or certification (specifically UN 38.3).
• Proven experience developing products for aerospace, defense, or similarly regulated environments.
• Experience supporting prototype, production, and test activities in a hands-on capacity.
• Advanced proficiency with CAD modeling and drafting (Solid Works preferred).
• Deep understanding of GD&T, mechanical drawing standards, and documentation control.
• Working knowledge of materials, composites, machined parts, and structural integration.
• Experience performing FEA and interpreting results for design optimization.
• Familiarity with PDM/PLM systems (e.g., Solid Works PDM, Windchill).
• Skills &
  
  Competencies:
  
  Strong technical leadership and decision-making skills;
  Excellent communication and collaboration across multi-disciplinary teams;
  Analytical mindset with strong problem-solving and root-cause analysis capabilities;
  Organized and detail-oriented with experience managing multiple design tasks simultaneously;
  Ability to mentor others and uphold engineering rigor and design quality.

• Master’s degree in Mechanical or Aerospace Engineering.
• 6–8 years of experience designing mechanical systems for UAS or defense applications.
• Experience leading subsystem integration efforts and participating in flight or environmental testing.
• Experience with advanced analysis tools (FEA, CFD, or…