Design Engineer, Battery Systems

Design Engineer, Battery Systems Direct Hire On Site in San Carlos, CA Salary Range: $120,000 - $160,000 annually Design Engineer We’re looking for a practical, hands-on Design Engineer to help develop flexible interconnects and battery connection systems for electric vehicles and energy storage. You’ll work and own your designs from early concept through production with a focus on making products that actually work, scale, and survive in the field.

Essential Duties and Responsibilities Design and build the core components that move power and data through the battery pack, including interconnects, current collector assemblies, busbars, voltage sense harnesses, and flexible circuits. Develop battery modules and pack layouts with a focus on manufacturability, serviceability, cooling, and system-level integration, making sure everything fits and functions inside the vehicle or enclosure. Create and manage detailed CAD models and engineering drawings for interconnects and PCBAs, using GD&T and stack-up analysis to define mechanical and assembly requirements.

Work hands-on through the full development cycle, from early prototyping to pilot builds and into production, troubleshooting designs as they evolve. Collaborate closely with cross-functional teams across mechanical, thermal, electrical, and manufacturing engineering. Turn system-level requirements into clear design specifications that meet performance, safety, and regulatory standards. Size and validate power distribution elements (busbars, flex, cables) using simulation and analytical methods like Joule heating and thermal modeling.

Select materials and define stack-ups to balance electrical performance, thermal behavior, and mechanical durability. Own and support validation activities, including DVP&R plans, DFMEA reviews, and Design for Manufacturability/Assembly (DFM/DFA) analysis. Serve as a technical point of contact for customers, managing relationships, facilitating design reviews, and ensuring alignment on requirements, timelines, and deliverables throughout the development process. Help lead engineering program management activities, including coordinating with suppliers, managing BOMs, tracking customer milestones, overseeing the design release process, and driving root cause investigations when issues arise.

Minimum Qualifications (Knowledge, Skills, and Abilities) Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or a related field. Minimum 4 years of experience working with electrical systems in industries such as aerospace, robotics, data centers, medical devices, appliances, or similar. Must be experienced in Vacuum lamination Must have electrical testing experience Must have laser and roll to roll/web handling experience Strong understanding of Li-ion battery cell formats (pouch, prismatic, cylindrical), including behavior, integration challenges, and design tradeoffs.

Experience in battery pack design, including series-parallel configurations, voltage/current balancing, and energy density optimization. Proficient in mechanical CAD tools such as Solid Works, NX, or equivalent. Familiar with cell connection manufacturing techniques such as laser welding, ultrasonic welding, and resistance welding. Knowledge of electrical joint design, mechanical fastening, and insulation strategies specific to battery systems. Understanding of End-of-Line testing requirements (HiPot, continuity, resistance, weld integrity) and ability to communicate them clearly in drawings and tooling documentation for low-volume/prototype builds.

Comfortable working with material properties for conductors, insulators, adhesives, and coatings. Strong hands-on prototyping, testing, and troubleshooting skills.

Experience with flex circuit manufacturing and related materials/processes is a plus. Familiarity with automotive or energy storage validation protocols and reliability testing is preferred. Physical Demands and Work Environment The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this position. Reasonable accommodations may be made to…