Senior Mechanical Design Engineer

Clarios; Plymouth; On-site; GBP 70,000 - 90,000; Full time

Benefits offered by this job

Medical, dental and vision care

401(k) with company match

Tuition reimbursement

Parental and caregiver leave

Paid time off and disability insurance

Job summary

Clarios seeks a Senior Mechanical Design Engineer to lead the mechanical design and development of advanced low-voltage and next-gen energy storage systems for automotive applications. You will own packaging, enclosures, and integration from concept through production, collaborating with systems, electrical, and manufacturing teams.

The role requires extensive automotive design experience, CAD tools proficiency, and DFMEA/DFPV knowledge.

Qualifications

• Bachelor’s degree in mechanical engineering or related engineering discipline.
• 8+ years of mechanical design experience.
• 5+ years of automotive product development experience.
• Proficiency with CATIA V5/V6, NX, Creo, or SolidWorks; GD&T (ASME Y14.5); PLM systems (Teamcenter, Windchill, or equivalent).
• Experience with mechanical analysis tools such as ANSYS, Abaqus, or HyperWorks.
• Knowledge of automotive product development processes (APQP, PPAP, DFMEA, DV/PV testing).
• Master’s degree in mechanical engineering (preferred).
• Experience designing battery systems, BMS packaging, power electronics enclosures, or energy storage products (preferred).

Responsibilities

• Lead mechanical design activities for automotive battery systems, battery packs, modules, BMS enclosures, power electronics housings, and thermal management components.
• Develop innovative mechanical architectures and packaging solutions for lead-acid, lithium-ion, sodium-ion, and hybrid energy storage systems.
• Create and release 3D CAD models, assemblies, detailed drawings, and GD&T documentation.
• Develop mechanical concepts considering performance, safety, manufacturability, serviceability, reliability, and cost targets.
• Coordinate mechanical design activities across global engineering teams.
• Perform or coordinate engineering analyses including: Structural FEA, Modal and vibration analysis, Thermal simulations, Fatigue and durability assessments, Tolerance stack-up analysis, DFMEA development.
• Act as the mechanical engineering lead on customer programs.
• Collaborate with manufacturing to ensure successful product industrialization and support prototype/pilot builds and production launch.
• Drive Design for Manufacturing/Design for Assembly/Design for Serviceability initiatives and supplier reviews.
• Interface with automotive OEM customers and suppliers; evaluate and approve technical designs.
• Mentor junior engineers and pursue continuous improvement and patent opportunities.

Skills

Mechanical design

Automotive product development

CATIA/NX/Creo/SolidWorks

GD&T

PLM systems

Finite element analysis

APQP/PPAP

DV/PV testing

Education

Bachelor's degree in mechanical engineering

Master's degree in mechanical engineering

Tools

Teamcenter

Windchill

ANSYS

Abaqus

HyperWorks

Job description

What you will do:

Clarios is seeking a highly motivated Senior Mechanical Design Engineer to lead the mechanical design and development of advanced low-voltage and next-generation energy storage systems for automotive applications. This role is responsible for the design, development, validation, and launch of battery systems, battery management hardware packaging, power electronics enclosures, and auxiliary energy storage products from concept through production. The Senior Mechanical Design Engineer will work closely with systems engineering, electrical engineering, manufacturing, quality, purchasing, suppliers, and OEM customers to develop innovative, robust, and cost- effective solutions that meet customer, regulatory, and manufacturing requirements.

How you will do it:

Product Development & Design

• Lead mechanical design activities for automotive battery systems, battery packs, modules, BMS enclosures, power electronics housings, and thermal management components.
• Develop innovative mechanical architectures and packaging solutions for lead-acid, lithium-ion, sodium-ion, and hybrid energy storage systems.
• Create and release 3D CAD models, assemblies, detailed drawings, and GD&T documentation.
• Develop mechanical concepts considering performance, safety, manufacturability, serviceability, reliability, and cost targets.
• Define material selections, joining methods, sealing strategies, structural designs, and enclosure architectures.
• Optimize designs for weight, volume efficiency, thermal performance, durability, and manufacturability.

Engineering Analysis & Validation

• Perform or coordinate engineering analyses including: Structural FEA, Modal and vibration analysis, Thermal simulations, Fatigue and durability assessments, Tolerance stack-up analysis, DFMEA development.

Program Leadership

• Act as the mechanical engineering lead on customer programs.
• Coordinate mechanical design activities across global engineering teams.
• Support project planning, technical reviews, and milestone deliverables.

Manufacturing & Launch Support

• Collaborate with manufacturing engineering to ensure successful product industrialization.
• Support prototype builds, pilot builds, and production launch activities.
• Drive Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Serviceability (DFS) initiatives.
• Support supplier technical reviews and component sourcing activities.

Customer & Supplier Interface

• Interface directly with automotive OEM customers regarding requirements, design reviews, validation results, and issue resolution.
• Work with suppliers to develop and qualify mechanical components and tooling.
• Evaluate supplier capabilities and approve technical designs.

Continuous Improvement

• Identify opportunities for product cost optimization and performance improvements.
• Support patent development and innovation initiatives.
• Mentor junior mechanical engineers and provide technical leadership within the organization.

What we look for:

Required:

• Bachelor’s degree in mechanical engineering or related engineering discipline.
• Minimum 8 years of mechanical design experience.
• Minimum 5 years of automotive product development experience.
• Proficiency using: CATIA V5/V6, NX, Creo, or SolidWorks; GD&T (ASME Y14.5); PLM systems (Teamcenter, Windchill, or equivalent).
• Experience with mechanical analysis tools such as ANSYS, Abaqus, or HyperWorks.
• Knowledge of automotive product development processes (APQP, PPAP, DFMEA, DV/PV testing).

Preferred:

• Master’s degree in mechanical engineering.
• Experience designing battery systems, BMS packaging, power electronics enclosures, or energy storage products.
• Familiarity with: Electric vehicle architectures; 12V and 48V electrical systems; Battery thermal management systems; Functional Safety (ISO 26262); Automotive cybersecurity concepts.

What you get:

• Medical, dental and vision care coverage and a 401(k) savings plan with company matching – all starting on date of hire
• Tuition reimbursement, perks, and discounts
• Parental and caregiver leave programs
• All the usual benefits such as paid time off, flexible spending, short-and long-term disability, basic life insurance, business travel insurance, and Employee Assistance Program
• Global market strength and worldwide market share leadership
• HQ location earns LEED certification for sustainability plus a full-service cafeteria and workout facility
• Clarios has been recognized as one of 2026’s Most Ethical Companies by Ethisphere. This prestigious recognition marks the fourth consecutive year Clarios has received this distinction.

Who we are:

Clarios is the force behind the world’s most recognizable car battery brands, powering vehicles from leading automakers like Ford, General Motors, Toyota, Honda, and Nissan. With 18,000 employees worldwide, we develop, manufacture, and distribute energy storage solutions while recovering, recycling, and reusing up to 99% of battery materials—setting the standard for sustainability in our industry. At Clarios, we’re not just making batteries; we’re shaping the future of sustainable transportation. Join our mission to innovate, push boundaries, and make a real impact. Discover your potential at Clarios—where your power meets endless possibilities.

Veterans/Military Spouses:

We value the leadership, adaptability, and technical expertise developed through military service. At Clarios, those capabilities thrive in an environment built on grit, ingenuity, and passion—where you can grow your career while helping to power progress worldwide. All qualified applicants will be considered without regard to protected characteristics.

Equal Employment Opportunity:

We recognize that people come with a wealth of experience and talent beyond just the technical requirements of a job. If your experience is close to what you see listed here, please apply. Diversity of experience and skills combined with passion is key to challenging the status quo. Therefore, we encourage people from all backgrounds to apply to our positions. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, age, status as a protected veteran or other protected characteristics protected by law. As a federal contractor, we are committed to not discriminating against any applicant or employee based on these protected statuses. We will also take affirmative action to ensure equal employment opportunities. Please let us know if you require accommodations during the interview process by emailing [e-mail]. We are an Equal Opportunity Employer and value diversity in our teams in terms of work experience, area of expertise, and all characteristics protected by laws in the countries where we operate. For more information on our commitment to sustainability, diversity, and equal opportunity, please read our latest report. We want you to know your rights because EEO is the law.