Key Responsibilities

1. Own the complete 3D Computer-Aided Design (CAD) architecture of the battery pack, including enclosure, module/cell-to-pack layout, busbars, interconnects, structural and mounting interfaces, and thermal management hardware
2. Develop and maintain master assemblies, detailed component drawings, Geometric Dimensioning and Tolerancing (GD&T), and tolerance stack-up analysis
3. Drive packaging optimization to meet two-wheeler (2W) design constraints, including weight, center of gravity, volumetric efficiency, IP rating, and vibration and shock durability
4. Maintain design documentation, Bill of Materials (BOM), and configuration and version control throughout the product lifecycle
5. Apply Design for Assembly (DFA) and Design for Manufacturing (DFM) principles from concept development to minimize part count, simplify assembly, reduce cycle time, and eliminate potential failure modes
6. Lead Design Failure Mode and Effects Analysis (DFMEA) reviews, incorporating error-proofing (poka-yoke), tolerance robustness, and serviceability into battery pack architecture
7. Optimize joining and interconnection strategies, including laser and ultrasonic welding, wire bonding, mechanical fasteners, and adhesives, to enhance manufacturability and reliability
8. Collaborate with suppliers and manufacturing teams to ensure product designs meet production volume, quality, cost, and manufacturability requirements
9. Identify and select suitable materials for enclosures, structural components, thermal interfaces, insulation, potting compounds, adhesives, gaskets, and fire and thermal propagation barriers
10. Evaluate mechanical performance, thermal behavior, flame retardancy, weight, cost, and recyclability to achieve an optimal balance in material and design selection
11. Establish material specifications, qualify suppliers, and support material validation and durability testing
12. Translate battery pack architecture into manufacturing processes, including process flows, work instructions, fixtures, tooling, and station-level requirements
13. Define process parameters, operating windows, and critical-to-quality (CTQ) requirements for welding, assembly, sealing, and testing operations
14. Lead root cause analysis and continuous improvement initiatives to enhance production yield, reduce cycle time and scrap, and improve overall product quality
15. Provide architectural and engineering support for the design, development, and commissioning of battery assembly lines
16. Define technical and operational requirements for critical manufacturing stations, including cell sorting and grading, stacking, welding, Building Management System (BMS), enclosure assembly, sealing and leak testing, and end-of-line (EOL) testing
17. Support equipment selection, production line layout, capacity planning, and production ramp-up in coordination with manufacturing and automation teams
18. Drive alignment between product design and manufacturing processes to ensure seamless integration and coordinated development throughout the product lifecycle
19. Coordinate with cell, BMS, thermal, electrical, and vehicle integration teams to align technical requirements and interface specifications
20. Ensure battery pack designs comply with applicable safety, regulatory, and homologation standards, including AIS-156, IEC 62133, UN 38.3, and relevant ISO/IEC standards
21. Mentor junior engineers by providing technical guidance, design expertise, and engineering support

Ideal Candidate

1. Bachelor's or Master's degree in Mechanical Engineering, Mechatronics, or a related engineering discipline
2. Overall 10–11 years of relevant experience in battery pack or Energy Storage System (ESS) design, with a strong understanding of lithium-ion battery technologies
3. Proficiency in 3D Computer-Aided Design (CAD) tools and mechanical design methodologies
4. Proven expertise in resolving complex structural, thermal, and packaging challenges
5. Strong knowledge of Design for Manufacturing (DFM) and Design for Assembly (DFA) principles
6. Hands-on experience in battery pack architecture, component integration, material selection, and manufacturing process development
7. Strong problem-solving, cross-functional collaboration, and technical leadership capabilities