Senior Design Engineer, Battery Systems

Senior Design Engineer, Battery Systems This position may require access to export-controlled information. In accordance with U.S. export control laws, candidates must qualify as a “U.S. Person” as defined by ITAR and/or EAR regulations. We’re looking for a practical, hands‑on Senior 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 5 years of experience working with electrical systems in industries such as aerospace, robotics, data centers, medical devices, appliances, or similar. 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 SolidWorks, 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. We’re hiring for multiple positions/levels and will align compensation accordingly. 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 enable individuals with disabilities to perform the functions. Physical Demands – Office and Manufacturing Environment While performing the duties of this position, the employee is regularly required to talk or hear. The employee frequently is required to use hands or fingers, handle, or feel objects, tools, or controls. The employee is required to stand, walk, sit, reach with hands and arms, pull/push, climb or balance, and stoop, kneel, crouch, or crawl. The employee must lift and/or move up to 50 pounds without assistance. Specific vision abilities required by this position include close vision, distance vision, color vision, peripheral vision, and the ability to adjust focus. Work Environment – Includes both a typical office environment, with minimal exposure to excessive noise or adverse environmental issues, and a shop environment, with exposure to high noise levels from operating machines, physical hazards from moving equipment and machine parts, nuisance dust, and skin exposure to chemicals used to run/maintain machines. PPE – May be required to wear Personal Protective Equipment, including but not limited to safety glasses, safety shoes, bump caps, gloves, hair nets, masks, & clean‑room frocks while adhering to the prescribed safety procedures. Working Conditions/Hours Salaried Exempt Compensation and Benefits The base pay is just one part of CelLink's total compensation package and is determined within a range. The pay range is designed to support your career progression as you learn, grow, and develop within your role. Your base pay range will depend on your skills, qualifications, experience, and location. At CelLink, we believe that each employee should have the opportunity to become a CelLink shareholder through participation in CelLink's discretionary employee stock option plan. You'll also receive comprehensive medical and dental coverage and other great benefits. Note: CelLink benefits, compensation, and employee stock programs are subject to eligibility requirements. San Carlos, CA Base Pay $140,000 — $160,000 USD We believe diversity and inclusion among our teammates are essential to our success. We celebrate diversity and are committed to creating an inclusive environment for all employees while building teams that represent a variety of backgrounds, perspectives, and skills. We are an equal opportunity employer. All employment is decided based on qualifications, merit, and business needs. CelLink participates in the E-Verify program in specific locations as required by law. #J-18808-Ljbffr