Battery Systems Engineer

Overview

EVolve Battery Systems designs and manufactures custom lithium‑ion battery packs for aerospace, defense, aviation, robotics, marine and industrial customers. The role is located in Boulder, CO and is full‑time, on‑site.

$95,000 – $140,000 per year.

• Design, build, and test lithium‑ion battery modules and packs, including mechanical harnessing, cooling hardware and quality checks.
• Read and review schematics, harness drawings, PCB layouts and ECAD/MCAD collaborations.
• Perform thermal modeling, liquid cooling basics, and validate heat‑generation targets with sensors and logging.
• Ensure high‑voltage safety through isolation resistance, hipot/dielectric testing, and leak/pressure checks for cooling circuits.
• Maintain compliance with UN38.3, IATA/DOT, UL2271/2580, and other relevant battery safety standards.
• Use BMS integration techniques for pre‑charge, HVIL, contractors, balancing, fault handling, and CAN diagnostics.
• Analyze test logs with Python/Num Py/Excel, and produce clear, versioned documentation such as DVP&R, test reports, and ECOs.
• Operate testing equipment (oscilloscopes, power supplies, loads, thermocouples, CAN tools) and own instrument calibration and data integrity.
• Collaborate on the whole product life cycle, from concept sizing and BOM creation to field support and continuous improvement.
• Communicate progress, risks, and decisions clearly to engineering, manufacturing and executive teams.

• BS/MS in Electrical or Mechanical Engineering, or equivalent hands‑on experience.
• 3–7 years of experience designing lithium‑ion packs/modules (cell selection, S/P topology, fuse and contactor sizing, thermal margins).
• Strong knowledge of BMS integration, CAN diagnostics and thermal management fundamentals.
• Experience with high‑voltage safety testing, isolation resistance, hipot, and pressure diagnostics.
• Understanding of UN38.3, IATA/DOT, UL2271/2580, and related regulatory requirements.
• Proficiency reading schematics, harness drawings, and PCB layouts; comfortable collaborating with ECAD/MCAD teams.
• Data fluency: experience parsing logs, performing quick analysis in Python/Num Py/Excel, and generating clear documentation.
• Hands‑on lab skills: bring‑up, oscilloscopes, power supplies, loads, thermocouples, CAN tools, and test result ownership.
• Independent work style, excellent communication, and the ability to meet deadlines without supervision.
• Nice to have: wire‑bonded cell experience (18650/21700), manifolded liquid cooling, pack sealing/IP ratings, participation in FSAE, Solid Works/Fusion for pack/mech trades, and experience selling or applying to aerospace/defense or industrial traction markets.
• 2+ years of assembling electro‑mechanical products (battery/EV/aerospace/industrial) with experience in mechanical drawings, wiring diagrams, torque tools, calibrated crimpers, DMM/continuity checks, and safety procedures.
• Knowledge of IPC‑A‑610/620 workmanship, harness building, mechanical basics (drilling, tapping, rivnuts), adhesives/sealants, cooling loops, and quality traceability.
• Safety awareness of high‑voltage environments (LOTO/PPE) and ability to lift 50 lbs and work in lab/manufacturing settings.
• Reliability and willingness to support critical builds and overtime when required.

The position offers a competitive salary, opportunities for professional growth, and a collaborative, hands‑on work environment in a growing aerospace and defense company.