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

1. 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.

2. 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.

3. CAE, Validation & Testing

Review CAE results (structural, crashworthiness, 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.

4. 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.

5. 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.