Mechanical Design Engineer – Battery Systems

Matchtech; Warwick; Remote; GBP 50,000 - 90,000; Full time

Job summary

An established industry player is seeking a Senior Mechanical Design Engineer to innovate in the field of electronics enclosures and battery systems. This role requires a proactive and detail-oriented engineer with a strong background in mechanical CAD and design principles. You'll be responsible for creating rugged designs that meet stringent environmental standards, collaborating closely with cross-functional teams to ensure production-ready solutions. If you thrive in a fast-paced environment and are passionate about engineering excellence, this opportunity is perfect for you.

Qualifications

• 8+ years of mechanical design experience in battery or electronics.
• Proficiency in Autodesk Fusion 360 or equivalent CAD tools.

Responsibilities

• Design ruggedized enclosures and battery modules for high-reliability applications.
• Collaborate with electrical and software teams for integrated designs.

Skills

Mechanical CAD

Design for Manufacturing (DFM)

Tolerance Stack-Up Analysis

Battery Module Design

Cable Harness Modelling

Problem-Solving Skills

Education

Bachelor's Degree in Mechanical Engineering

Tools

Autodesk Fusion 360

Job description

This role is Outside IR35

UK based Remote working

Job Title:

Senior Mechanical Design Engineer – Electronics Enclosure & Battery Systems

Role Overview:

The Senior Mechanical Design Engineer will be responsible for designing ruggedized enclosures, battery modules, and supporting systems. The ideal candidate will have expertise in mechanical CAD, materials, and manufacturing techniques for high-reliability applications. This position suits a proactive, detail-oriented engineer who works well in a collaborative and fast-paced environment.

Key Responsibilities:

1. Develop and manage mechanical designs using Autodesk Fusion 360 or equivalent CAD tools (license required or provided by candidate).
2. Design battery packs and busbars for power systems, ensuring safety, reliability, and thermal performance.
3. Create enclosure designs meeting IP67–IP68 ingress protection standards.
4. Apply DFM/DFA principles for plastic moulding, sheet metal, and laser welding fabrication.
5. Perform tolerance stack-up analysis and ensure electrical clearance and creepage compliance.
6. Model cable harnesses and design effective strain relief and routing strategies.
7. Select and implement robust fixing methods: adhesives, rivets, welds, mechanical fasteners.
8. Ensure designs comply with environmental and mechanical standards including corrosion, dust & sand ingress, shock & vibration, and water immersion standards.

Standards include:

• Corrosion: AECTP–300 Method 309
• Dust & Sand: AECTP–300 Method 313
• Shock & Vibration: DEF STAN 00–35 (M1–M6)
• Rain, Solar, Immersion: AECTP–300 Methods 305, 307, 310

Collaboration:

Work closely with electrical, software, and manufacturing teams to ensure integrated, production-ready designs. Occasional on-site system integration activities in the UK may be required (location to be confirmed).

Requirements:

• Minimum 8 years of mechanical design experience in battery, electronics, or automotive industries.
• Proficiency with Autodesk Fusion 360 or similar MCAD tools (must provide own license if not using Fusion 360).
• Proven experience in:

• Battery module and busbar mechanical design
• Enclosure design with IP67–IP68 protection
• Harness and cable modelling
• Plastic injection moulding and sheet metal design
• Laser welding and other joining techniques
• Tolerance analysis and electrical safety spacing
• Designing for mass manufacturing and assembly

• Deep understanding of environmental and mechanical compliance standards.

Preferred Skills:

• FEA or simulation experience in thermal, static, or dynamic mechanical loading scenarios.
• Experience in rugged environments (defence, automotive, industrial sectors).
• Experience working in a milestone-driven development environment.

Personality:

• Initiative-taker with a creative and solutions-focused mindset.
• Strong communication and problem-solving skills.
• Comfortable working independently and delivering results.