Senior Mechanical Design Engineer

Senior Mechanical Design Engineer

Location:

San Jose, CA

Employment Type:

Full-Time

About the Company:

We are a stealth-mode battery startup developing cutting-edge battery technology. Our mission is to revolutionize battery technology to accelerate the global transition to clean energy. By leveraging innovative materials, advanced manufacturing techniques, and next-generation energy storage architectures, we are building the future of sustainable energy.

About the Role:

We are seeking a Senior Mechanical / Product Design Engineer to lead the design and development of advanced structural enclosures for high-performance battery systems. This role focuses on designing robust, manufacturable, and scalable structures such as enclosures, trays, and lids that manage complex mechanical loads between the energy system and its host structure.

The ideal candidate combines strong mechanical design fundamentals with an understanding of material tradeoffs, manufacturing technologies, and product architecture optimization. You will collaborate closely with analysis, testing, and manufacturing teams to translate conceptual designs into production-ready hardware that meets demanding performance and reliability requirements.

• Own the design of structural components such as enclosures, trays, and covers that manage thermal, mechanical, and environmental loads.
• Lead architectural studies to explore tradeoffs across weight, stiffness, cost, manufacturability, and system-level impacts including energy performance, part interdependencies, and manufacturability.
• Drive optimization efforts with cross-functional teams, customers, and vendors to achieve robust, efficient, and manufacturable designs.
• Integrate design-for-manufacturing (DFM) and design-for-assembly (DFA) principles into all development stages.
• Ensure proper sealing, structural integrity, and corrosion resistance across all structural interfaces.
• Provide directional guidance through simulations to steer the design and architecture when dedicated CAE resources are limited.
• Develop comprehensive 2D drawing packages applying appropriate GD&T and conduct tolerance analyses to ensure assembly integrity and performance.

• Select materials and processes suitable for performance, manufacturability, and cost, balancing tradeoffs across multiple engineering and production considerations.
• Apply knowledge of manufacturing technologies such as sheet metal forming, extrusion, high-pressure die casting, welding, adhesive bonding, fasteners, and coating technologies.
• Work with internal and external partners to define tolerances, specifications, and production intent designs.
• Oversee suppliers from initial engagement through delivery, inspection, and validation of parts.

• Partner with CAE, test, and systems engineering teams to ensure designs meet performance and safety requirements.
• Collaborate with manufacturing, quality, and test teams to ensure design intent is realized in hardware.
• Communicate complex mechanical tradeoffs and decisions clearly to internal teams, partners, and customers.

• Support component and system-level validation, including vibration, structural, and environmental testing.
• Support in validation, durability, and abuse testing activities to ensure performance and reliability.
• Drive root-cause analysis and corrective actions for mechanical performance issues.

• B.S. or M.S. in Mechanical Engineering, Applied Mechanics, or a related field.
• 7+ years of experience in mechanical or product design for structural systems (battery structures preferred; body structures also applicable).
• Strong understanding of mechanical loads, materials behavior, and product lifecycle considerations.
• Experience with CAD tools (e.g., CATIA, NX, Solid Works, or similar).
• Familiarity with mechanical FEA tools (Abaqus, ANSYS, LS-DYNA, etc.) to provide guidance on simulation and validation.
• Proven experience working with suppliers from concept through delivery and testing.
• Knowledge of leak testing methods and structural validation processes is a plus.
• Familiar it…