Senior Mechanical Design Engineer

About Brelle

"Energy for what moves us" defines our mission  develop frontier technology that pushes what's possible in electrified performance. Based in California, Brelle engineers next-generation platforms for supercars and superbikes, working alongside leading high-performance brands across the US and Europe. Our innovations are built on a novel pack architecture, a full-stack software platform, and an advanced approach to automated manufacturing. Joining the team means working on making electric vehicles-on the road and on the racetrack-lighter, more engaging, safer, and capable of charging in minutes.

Our engineering teams are structured like small Skunk works teams - nimble, cross-functional, and technical. Engineers are encouraged to explore new concepts and materials and expected to rapidly go from concept idea to prototype. Brelle engineers are given a high level of autonomy to develop and release their parts across programs.

Role Responsibilities

• Own the design for a new module architecture- cell retention systems, thermal management strategies, safety systems, housing integration, and electromechanical interfaces
• Work with cylinder and pouch cell formats in 400-1000V systems, optimizing weight, thermal performance, cost, and manufacturing feasibility
• Collaborate cross-functionally with Brelle's electrical, thermal, simulation, and software teams to optimize the complete battery pack package
• Coordinate design work with pack team members to converge on feasibility for function, manufacturing, and reliability of modules in pack and vehicle
• Develop a robust cell venting strategy and propagation protection while meeting manufacturing and cost targets
• Identify and suggest missing requirements needed and drive completion of released requirements

Technical Qualifications

• Bachelor's or master's degree in mechanical engineering (or equivalent with demonstrated depth)
• 5+ years of mechanical design experience in automotive or motorcycle battery/powertrain development
• Advanced CAD proficiency in CATIA V5/V6 (3DX), NX, or Solid Works: complex assemblies, GD&T, production drawings
• Robust understanding of lithium-ion cell as it relates to electromechanical and safety design constraints
• Understanding of battery system architectures and HV safety requirements (400V+ systems)
• Hands-on structural FEA experience: defining load cases, boundary conditions, interpreting results for design decisions
• Experience with DFM for multiple processes: injection molding, stamping, casting, composites, machining, fabricating
• Experience with DFMEA/DVP&R cycles and design release processes
• Battery module or pack design experience-you've navigated cell-level constraints and thermal management complexity

Preferred Qualifications

• Practical hands-on experience in professional or personal projects - interest in working directly on the parts/products in the lab
• Thermal simulation experience (CFD or equivalent)-you understand heat transfer, material selection implications and can develop solutions to meet system-level requirements
• Design experience integrating into vehicle platforms-you understand powertrain architecture and integration challenges
• Experience working at or with automotive OEMs or Tier-1 Suppliers on electrified platforms.
• Proven track record releasing components to production: you've worked in a high-pace environment, participated in design reviews, and understand how designs move from concept to production level parts

You are...

• Fundamentally Curious - driven by a deep curiosity and motivated to break down complex problems to their first principles, allowing you to think outside the box and develop innovative design solutions
• Organized and Meticulous - possess an obsessive attention to detail, able to recognize efficiency in design, and always striving for the optimal solution
• Self-Motivated and Autonomous - highly self-motivated, capable of managing your own workload, taking ownership of projects, and driving tasks forward with minimal supervision
• Results-Oriented - driven by results and maintain a clear focus on the end goal while executing detailed tasks
• Collaborative Team Player - strong team player who actively supports teammates, communicates effectively, and contributes positively to the collective success of the teams
• Humble and Open-Minded - willing to accept feedback and learn, constantly seeking out new knowledge and integrating feedback to improve yourself and the products you own

Compensation & Benefits

Compensation

• Base Salary: $140,000 - $175,000. Compensation may vary based on experience, training, education, and scope of the role.
• Founding Engineer equity participation through Employee Incentive Plan

Benefits

• Medical (HMO, PPO), Dental, and Vision
• 401(k)
• Flexible PTO

Culture

• Team meals 2x per week
• Monthly team events