Senior Product Design Engineer

Senior Product Design EngineerWe are a stealth-mode battery startup developing cutting-edge battery technology. Our mission is to revolutionize battery technology to accelerate the global transition to clean energy. By leveraging innovative materials, advanced manufacturing techniques, and next-generation energy storage architectures, we are building the future of sustainable energy.We are seeking a Senior Product Design Engineer to lead the design and development of advanced structural enclosures for high-performance battery systems. This role focuses on designing robust, manufacturable, and scalable structures such as enclosures, trays, and lids that manage complex mechanical loads between the energy system and its host structure.The ideal candidate combines strong mechanical design fundamentals with an understanding of material tradeoffs, manufacturing technologies, and product architecture optimization. You will collaborate closely with analysis, testing, and manufacturing teams to translate conceptual designs into production-ready hardware that meets demanding performance and reliability requirements.Mechanical Design & ArchitectureOwn the design of structural components such as enclosures, trays, and covers that manage thermal, mechanical, and environmental loads.Lead architectural studies to explore tradeoffs across weight, stiffness, cost, manufacturability, and system-level impacts including energy performance, part interdependencies, and manufacturability.Drive optimization efforts with cross-functional teams, customers, and vendors to achieve robust, efficient, and manufacturable designs.Integrate design-for-manufacturing (DFM) and design-for-assembly (DFA) principles into all development stages.Ensure proper sealing, structural integrity, and corrosion resistance across all structural interfaces.Provide directional guidance through simulations to steer the design and architecture when dedicated CAE resources are limited.Develop comprehensive 2D drawing packages applying appropriate GD&T and conduct tolerance analyses to ensure assembly integrity and performance.Materials & ManufacturingSelect materials and processes suitable for performance, manufacturability, and cost, balancing tradeoffs across multiple engineering and production considerations.Apply knowledge of manufacturing technologies such as sheet metal forming, extrusion, high-pressure die casting, welding, adhesive bonding, fasteners, and coating technologies.Work with internal and external partners to define tolerances, specifications, and production intent designs.Oversee suppliers from initial engagement through delivery, inspection, and validation of parts.Cross-Functional CollaborationPartner with CAE, test, and systems engineering teams to ensure designs meet performance and safety requirements.Collaborate with manufacturing, quality, and test teams to ensure design intent is realized in hardware.Communicate complex mechanical tradeoffs and decisions clearly to internal teams, partners, and customers.Validation & TestingSupport component and system-level validation, including vibration, structural, and environmental testing.Support in validation, durability, and abuse testing activities to ensure performance and reliability.Drive root-cause analysis and corrective actions for mechanical performance issues.QualificationsB.S. or M.S. in Mechanical Engineering, Applied Mechanics, or a related field.7+ years of experience in mechanical or product design for structural systems (battery structures preferred; body structures also applicable).Strong understanding of mechanical loads, materials behavior, and product lifecycle considerations.Experience with CAD tools (e.g., CATIA, NX, SolidWorks, or similar).Familiarity with mechanical FEA tools (Abaqus, ANSYS, LS-DYNA, etc.) to provide guidance on simulation and validation.Proven experience working with suppliers from concept through delivery and testing.Knowledge of leak testing methods and structural validation processes is a plus.Familiarity with industry standards and regulations for structural or energy storage systems is a plus.Excellent communicator capable of presenting to multidisciplinary teams.Comfortable working in fast-paced, iterative environments with evolving product requirements.Why Join?Innovative Technology: Work on cutting-edge energy storage solutions that power the future.Career Growth: Opportunities to work on high-impact projects and advance in a growing industry.Competitive Benefits: Comprehensive health, wellness, and professional development programs.Mission-Driven Culture: Be part of a team that is shaping the future of sustainable energy through innovation and excellence.We are an equal opportunity employer and we do not discriminate on the basis of race, gender, sexual orientation, gender identity/expression, national origin, disability, age, genetic information, veteran status, marital status, pregnancy or related condition, or any other basis protected by law.