EV Battery Pack Design Engineer

W3Global; Banbury; Hybrid; GBP 60,000 - 85,000; Full time

Job summary

W3Global is seeking an experienced EV Battery Pack Design Engineer in Banbury to design and validate high-voltage packs for electric vehicles. The role focuses on mechanical packaging, CAD modelling, and engineering release while collaborating with cross-functional teams to meet performance, safety, quality and cost targets.

The ideal candidate has 5+ years in automotive design engineering, strong CATIA V5/V6 skills, and solid GD&T and DFMEA/DVP&R experience.

Qualifications

• Bachelor's or Master's in Mechanical Engineering, Automotive Engineering, or related discipline.
• 5+ years of automotive design engineering experience, preferably EV battery pack development.
• Proficiency in CATIA V5 and CATIA V6 for CAD design.
• Strong GD&T knowledge and DFMEA/DVP&R familiarity.
• Experience with BOM management and engineering release processes.

Responsibilities

• Battery Pack Design & Packaging: enclosures, structural parts, cooling systems, busbars, brackets, mounting.
• Create 3D CAD models, assemblies, 2D drawings, and BOMs.
• Support packaging studies for vehicle integration, serviceability, manufacturability and safety.
• Define interfaces and packaging constraints; ensure DFMEA and design reviews run smoothly.
• CAe validation support: review analyses and implement design improvements.
• Support DV/PV testing, environmental testing and vibration; aid root cause analyses.
• Coordinate with battery, thermal, electrical, BMS, manufacturing and vehicle teams.

Skills

Mechanical design

CA/CE interpretation

GD&T

Engineering release processes

BOM management

Education

Bachelor's or Master's in Mechanical/Automotive Engineering

Tools

CATIA V5

CATIA V6

Job description

Job Title: EV Battery Pack Design Engineer

Location: Banbury, UK

Duration: 12 months fixed term employment

No of positions: 1

Hybrid work model: 5 days/week from client location

Experience: 5-12 Years Domain: Electric Vehicles, Battery Pack Engineering, Energy Storage Systems

About The Role

We are looking for a skilled EV Battery Pack Design Engineer to support the design, development, and validation of high-voltage battery packs for electric vehicles. The role focuses on mechanical design, packaging, thermal integration, component development, CAD modelling, and engineering release activities while working closely with cross-functional teams to meet performance, safety, quality, and cost targets.

Key Responsibilities

• Battery Pack Design & Packaging


• Design and develop battery pack components including enclosures, structural parts, cooling systems, busbars, brackets, and mounting systems.


• Create 3D CAD models, assemblies, 2D drawings, and BOMs.


• Support battery pack packaging studies considering vehicle integration, serviceability, manufacturability, and safety requirements.


• Define and manage component interfaces and packaging constraints.


• Mechanical Design & Product Development


• Develop detailed designs from concept through production release.


• Apply GD&T principles and engineering standards in component design.


• Support DFMEA, DVP&R, design reviews, and engineering change management activities.


• Collaborate with suppliers and internal teams for component development and issue resolution.


• Ensure compliance with DFM/DFA guidelines and automotive quality standards.


• CAE & Validation Support


• Work with CAE teams to support structural, thermal, vibration, and crash simulations.


• Review simulation results and implement design improvements.


• Support DV/PV testing, environmental testing, vibration testing, and performance validation.


• Participate in root cause analysis and corrective action implementation.


• Cross-Functional Collaboration


• Coordinate with battery, thermal, electrical, BMS, manufacturing, and vehicle integration teams.


• Support technical discussions with suppliers and program stakeholders.


• Track engineering deliverables, open issues, and design changes throughout the development cycle.


• Ensure timely release of engineering documentation and design updates.


• Manufacturing & Launch Support


• Support prototype build activities and production trials.


• Collaborate with manufacturing teams on tooling, assembly processes, and design optimization.


• Participate in PFMEA reviews and process validation activities.


• Support launch readiness and production issue resolution.

Required Skills & Qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Automotive Engineering, or related discipline.


• 5+ years of experience in automotive design engineering, preferably in EV battery pack development.


• Proficiency in CAD tools such as CATIA V5 & CATIA V6.


• Strong understanding of sheet metal, castings, extrusions, plastics, and structural design.


• Experience with GD&T, DFMEA, DVP&R, BOM management, and engineering release processes.


• Knowledge of battery pack structures, thermal management systems, and HV component integration.


• Ability to interpret CAE and test results for design optimization.


• Strong problem-solving, communication, and teamwork skills.

Preferred Qualifications

• Experience working with EV OEMs or Tier-1 suppliers.


• Knowledge of lithium-ion battery systems and HV safety requirements.


• Familiarity with battery pack manufacturing processes such as welding, bonding, sealing, and assembly.


• Exposure to PLM tools.


• Experience supporting prototype builds and production launches.


• Understanding of automotive standards and regulations related to EV battery systems.