Jobs in Poole, United States

This role is Outside IR35

UK based Remote working

Senior Mechanical Design Engineer – Electronics Enclosure & Battery Systems

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.

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

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).

• 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.

• 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.

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