EV Battery Pack Lead Engineer Foster City, CA

EV Battery Pack Lead Engineer

We are looking for a highly skilled EV Battery Pack Lead Engineer to lead end-to-end design, development, validation, and industrialization of high-voltage battery packs for electric vehicles. This role requires strong technical depth in battery systems, engineering leadership, cross-functional collaboration, and the ability to drive design decisions that meet performance, safety, cost, and timing targets.

Key Responsibilities

• Battery Pack Architecture & System Design
• Lead the development of HV battery pack architecture, module configuration, cooling strategy, HV/LV distribution, and structural layout.
• Define system requirements, technical specifications, and Interface Control Documents (ICDs).
• Conduct trade-off studies considering cell format, thermal behavior, crash safety, cost, manufacturability, and packaging constraints.
• Detailed Design & Engineering Leadership
• Guide mechanical, thermal, electrical, and BMS engineers throughout the design cycle.
• Review CAD models, drawings, GD&T, DFMEA, and DVP&R documentation.
• Ensure DFM/DFA best practices and compliance with industry standards (UN38.3, UL2580, ISO 26262, ISO 6469).
• Manage supplier technical interactions for cells, cooling plates, BMS, enclosures, and busbars.
• CAE, Validation & Testing
• Review CAE results (structural, crash worthiness, vibration, thermal/CFD).
• Define and execute validation plans including DV, PV, abuse testing, IP rating, vibration, shock, and regulatory compliance.
• Drive correlation between CAE and physical test results.
• Program & Stakeholder Management
• Lead technical discussions with customers, suppliers, and cross-functional teams.
• Manage technical risks, open issues, ECO/ECN processes, and release gates.
• Provide status updates, review technical deliverables, and ensure timely milestone achievements.
• Industrialization Support
• Support prototype builds, plant trials, PFMEA, and control plan development.
• Coordinate with manufacturing engineering for tooling, fixtures, assembly sequence, and process validation.
• Ensure readiness for PPAP and SOP.

Required Skills & Qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Electrical Engineering, Automotive Engineering, or equivalent.
• Experience in EV battery pack or energy storage system design.
• Strong knowledge of lithium-ion cell technology, thermal management, HV safety, and mechanical structures.
• Proficiency in CAD tools (CATIA V6) and PLM systems.
• Good understanding of CAE concepts and ability to interpret simulation results.
• Hands-on experience with DV/PV testing and correlation.
• Excellent problem-solving, leadership, and communication skills.
• Familiarity with automotive standards and regulations relevant to EV battery systems.

Preferred Qualifications (Nice to Have)

• Experience with ISO 26262 functional safety for BMS.
• Prior exposure to global EV OEMs/Tier-1s.
• Knowledge of pack manufacturing processes (welding, bonding, potting, gasketing).
• Experience in HV/LV architecture, wiring, and controls.
• Agile/SAFe program management experience.

Working Place:
Foster City, California, United States

Company: ESR Healthcare