Principal Mechanical Design Engineer - (Battery & EV Charging)

Perfect Storm Software, LLC; Bicester; Hybrid; GBP 50,000 - 90,000; Full time

Job summary

An innovative company is seeking a Principal Mechanical Design Engineer to spearhead the development of cutting-edge charging systems. In this pivotal role, you will oversee the design and release process for high-performance products, ensuring they meet quality, cost, and functionality targets. Your expertise in mechanical and product design will be crucial in shaping user-centric solutions while adhering to regulatory standards. This position offers a unique opportunity to drive advancements in electric vehicle technology and contribute to a sustainable future. Join a dynamic team and make a significant impact in the mobility sector.

Qualifications

• Minimum 5 years experience in the mobility sector (automotive, charging, battery, or EVs).
• Strong knowledge of battery technologies, including cell chemistries and BMS systems.

Responsibilities

• Lead the design and development of mechanical systems, products, and components.
• Ensure product performance meets key engineering targets through rigorous validation.

Skills

Mechanical Design

Product Design

CAD Software Proficiency

Battery Technologies

Thermal Management Systems

FMEA

Structural Analysis

Education

MEng in Mechanical Engineering

Tools

CAD Software

Analytical Tools

Job description

Principal Mechanical Design Engineer - (Battery & EV Charging)

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Principal Mechanical Design Engineer

Bicester, Oxfordshire

Permanent

As the Principal Mechanical Design Engineer, you will be responsible for the development of all physical components within our advanced charging systems. This encompasses primary and secondary structures, control panels, high-voltage (HV) and low-voltage (LV) sub-systems, wiring harnesses, and thermal management systems. This hands-on leadership role involves defining architecture, developing mechanical frameworks, and steering the transition to full-scale production.

In this role, you will take ownership of the design and release process for our high-performance charging systems, aligning with our strategic roadmap. You will be instrumental in shaping the certification process and ensuring design-for-manufacture principles are met while maintaining critical quality, cost, functionality, weight, and timing targets. Responsibilities will also include testing and validation of physical systems, such as high-voltage batteries, grid-connected AC-DC units, and high-power DC charging infrastructure.

A good understanding of electric vehicle (EV) / charging infrastructure and associated technologies is required for this role. Additionally, you must possess a balanced blend of mechanical design expertise and product/industrial design knowledge to drive the development of high-quality, user-centric products. This cross-disciplinary approach will ensure our products are not only mechanically sound but also aligned with practical and aesthetic design principles for end-user satisfaction.

This is an exceptional opportunity to drive the development, testing, and validation of a core product within a fast-growing, dynamic company. The ideal candidate will have a solid background in mechanical and design engineering, with substantial experience in electric vehicle (EV) technologies, including structural components, cooling systems, battery integration, and charging hardware. A hands-on approach is essential, along with the ability to develop innovative concepts and support system assembly on the production line.

Responsibilities

Lead the design and development of mechanical systems, products, and components, developing and validating engineering designs.

oEnsure product performance meets key engineering targets through rigorous validation.

oDesign and integrate cooling and heating systems for EV and power electronics.

oSelect materials and components, producing detailed CAD drawings.

oDevelop and maintain system and component-level DFMEAs.

Own and run the in-house build & test lab.

oPrototype designs to support product verification and market entry strategies.

oConduct feasibility assessments and cost-benefit analyses to ensure design viability.

oIdentify and resolve design and manufacturing challenges using CAD and analytical tools.

oInterpret and adhere to regulatory requirements, defining appropriate testing strategies.

oDeliver concept schemes, final designs, and release drawings in line with project goals.

Drive continuous and iterative improvement across the product function.

oLead change management initiatives, root cause analyses, and corrective actions.

oManage Design Verification Plan & Report schedules to ensure compliance and certification.

oProvide technical mentorship to technicians and support production processes.

oOversee engineering release processes from concept to finalized documentation.

Manage supplier, partner & industry engagement.

oAssist in creating RFQ/RFI documentation and support supplier interactions.

oWork closely with suppliers to refine cost, manufacturability, and design quality.

oStay informed about industry standards, regulations, and emerging technologies.

________________________________________

Qualifications

Must-haves

MEng degree in mechanical, electrical, or automotive engineering.

Minimum of five years experience in the mobility sector (automotive, charging, battery, or EVs).

Good experience with EV /charging infrastructure, including AC-DC units, high-power DC charging, and associated systems.

Proven capability in both mechanical design and product/industrial design processes, ensuring products are optimized for function, usability, and visual appeal.

Experience with mechanical and electrical EV components, including CAN protocol.

Strong knowledge of battery technologies, including cell chemistries and BMS systems.

Proficiency in CAD software.

Expertise in materials, pressings, and volume manufacturing techniques.

Experience in structural analysis (stress, stiffness, fatigue, optimization).

Ability to analyze test data and correlate with simulation results.

Understanding of battery characteristics, thermal systems, and pack cooling.

Strong foundation in fluid mechanics and heat transfer principles.

Comprehensive knowledge of GD&T, drawing standards, and assembly documentation.

Familiarity with safe handling of HV systems and regulatory compliance.

Experience with system/component delivery, including FMEA, quality planning, and PPAP.

Ability to work independently in a dynamic, process-light environment.

Hybrid work model (minimum 3 days on-site in Bicester).

Self-motivated, collaborative, and a strong team player.

Eligible to work in the UK.

Nice-to-haves

Experience working with EV charging or Battery Energy Storage systems.

Knowledge of fleet vehicle (eLCV and eHGV) technologies is advantageous.

Ability to challenge experts, consultants, and seniors by presenting a measured systematic first-principles approach.

Strong understanding of EV charging standards and protocols.

________________________________________

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Seniority level

• Seniority level

  Mid-Senior level

Employment type

• Employment type

  Full-time

Job function

• Industries

  Machinery Manufacturing

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