Mechanical Engineer - Battery Pack Design

Mechanical Engineer: Battery Pack Design Zēlos® Energy is an innovative battery startup headquartered in the San Francisco Bay Area, and a leader in developing safe, sustainable, and proven rechargeable zinc-based chemistries. Our company is at an exciting juncture from R&D to production, for applications including stationary storage for power backup and data centers. We are seeking a Mechanical Engineer, Battery Pack Design, to lead the design, development, and validation of advanced battery pack systems for high-performance applications. This role requires a strong background in mechanical design, thermal management, and structural analysis, with a focus on safety, manufacturability, and reliability. The ideal candidate is available full-time on-site at our lab facility in San Leandro. Key Responsibilities Design battery pack enclosures, modules, and mechanical components from concept through design for manufacturing. Perform structural, thermal, and vibration simulations to ensure performance under real-world conditions. Collaborate with electrical, thermal, and manufacturing teams to integrate cells, BMS, and cooling systems. Develop CAD models, engineering drawings, and BOMs using CAD tools. Conduct design reviews, FEA simulations, and tolerance stack‑up analyses. Support prototyping, testing, and validation activities, including failure analysis and root cause investigations. Ensure compliance with safety standards and regulations (e.g., UL, IEC, UN38.3). Work with suppliers and manufacturing partners to optimize design for cost, scalability, confidentiality, and production efficiency. Qualifications Bachelor’s or master’s degree in mechanical engineering or related field. 3+ years of experience in battery pack design, automotive, aerospace, or energy storage systems. Proficiency in CAD software and simulation tools (FEA/CFD). Strong understanding of thermal management, materials, and structural design. Experience with design for manufacturability (DFM) and design for assembly (DFA). Collaborative, hands‑on approach and desire to work in a startup. Reside within reasonable commuting distance of San Leandro, California. Candidates must be fully authorized to work for any employer in the US. Unfortunately, we are unable to sponsor or transfer visas for this role. Preferred Skills Familiarity with battery technologies (Alkaline and Zinc‑based chemistries, Lead‑Acid, Li‑ion, etc.) and safety considerations. Knowledge of cooling systems (liquid, air, or phase‑change). Hands‑on experience with prototyping, testing, and validation. Strong problem‑solving skills and ability to work in cross‑functional teams. Flexible with both creating and responding to evolving requirements and priorities over time. Compensation and Benefits Full‑time compensation of $120K to $145K depending on experience and expertise. Generous 401(k) and stock options. Free all‑day parking lot adjacent to I-880, free shuttle from San Leandro BART, complimentary office snacks and beverages. Access to Gate 510 incubator space with large common atrium and kitchen area. Paid holidays and unlimited PTO. Excellent medical, dental, and vision benefit options. #J-18808-Ljbffr Zēlos Energy Ltd