Battery pack design and manufacturing engineer (Carlsbad)

Company Description American Lithium Energy Corporation is an advanced battery technology company focused on designing and manufacturing high-performance lithium-based energy storage solutions. The company serves a range of applications where reliability, safety, and high energy density are critical, including commercial, industrial, and specialized markets. Team members collaborate closely across engineering and manufacturing to bring innovative battery products from concept to production. Working at American Lithium Energy Corporation offers opportunities to contribute to cutting-edge power solutions and grow in a fast-paced, technology-driven environment.

Role Description The Battery Pack Design and Manufacturing Engineer will be responsible for designing, developing, and optimizing battery pack assemblies from concept through production. Day-to-day tasks include creating mechanical and electrical designs, specifying components and materials, generating drawings and documentation, and coordinating with manufacturing teams to ensure robust, scalable processes. The role involves hands-on support on the production floor, troubleshooting design and process issues, implementing design for manufacturability (DFM) improvements, and collaborating with cross-functional teams on testing, validation, and quality assurance. This is a full-time, on-site role based in Carlsbad, CA, requiring regular interaction with engineering, operations, and quality personnel to meet performance, safety, and cost targets.

Key Responsibilities

• Battery Pack Design & Development
• Design and develop lithium-ion battery packs
• Develop mechanical design concepts including module structures, busbars, terminals, cooling plates, etc.
• BOM preparation and cost optimization.
• BMS & Electronics Integration
• Work with BMS teams for hardware and firmware integration.
• Define protection parameters: OVP, UVP, OCP, OTP, short circuit limits, SOC/SOH algorithms.
• Support SMbus and CAN communication development
• Testing & Validation
• Develop DVP&R (Design Validation Plan & Report) for battery packs.
• Conduct electrical, thermal, mechanical, vibration, and environmental tests.
• Analyze test data and generate technical reports.
• Perform failure analysis (cell, module, pack-level failures).
• Prototype Development
• Oversee prototype pack assembly and testing.
• Collaborate with production for smooth transfer from design stage to mass manufacturing.
• Validate fixtures, jigs, and assembly processes.
• Standards & Certification
• Work with purchase, quality, production, and service teams.
• Support customer technical discussions
• Benchmark competitor battery packs and technologies.

Qualifications

• Strong background in Design Engineering and Product Design for battery packs or related electromechanical systems.
• Knowledge of Manufacturing Processes with experience translating designs into efficient, repeatable production methods.
• Experience in Manufacturing Engineering, including process optimization, tooling, and production line support.
• Solid foundation in Mechanical Engineering, including materials, structural design, thermal considerations, and CAD tools.
• Bachelor’s degree in mechanical engineering, Electrical Engineering, or a related field, or equivalent practical experience.
• Experience with battery pack design, lithium-ion cells, safety standards, and validation/testing protocols is highly beneficial.
• Ability to read and create technical drawings, specifications, and documentation with attention to detail and quality.
• Strong problem-solving skills, ability to work collaboratively on-site, and effective communication with cross-functional teams.