Battery Electrical Engineer

BayOne; Mountain View (CA); On-site; USD 150,000 - 190,000; Full time

Job summary

BayOne seeks a Battery Electrical Design Engineer to lead HV battery systems for eVTOL propulsion, bridging cell-level energy storage to aircraft power conversion.

You will drive electrical architecture from concept to flight-certified hardware, focusing on safety-critical HV systems, EMI/EMC, and DO-160 compliance to enable robust aerospace energy storage solutions.

Qualifications

• 8+ years in electrical design for HV systems
• Experience with aerospace standards DO-160G/DO-311A
• Experience with Battery Management System hardware and sensing
• Proficient ECAD and PCB layout for high-power applications

Responsibilities

• Architect HV power distribution and interface with power electronics
• Lead design of battery modules and pack sensing and interconnects
• Develop on-board and off-board charging systems per CCS/MCS/NACS
• Perform electrical modeling, power budget, and fault-current analysis
• Lead EMI/EMC strategies, grounding, and shielding per DO-160

Skills

HV Power Systems Design

High-Voltage 400V+

System Architecture

FMEA

Harness & Busbar integration

Education

Electrical Engineering degree (B.S./M.S./Ph.D.)

Tools

LTspice/PSpice

MATLAB/Simulink

Altium

Mentor Graphics

Zuken

Job description

We are seeking a Battery Electrical Design Engineer to serve as a primary technical authority for our high-voltage (HV) battery systems and power distribution architectures. In this role, you will lead the electrical development of safety-critical propulsion systems for our eVTOL aircraft, bridging the gap between cell-level energy storage and aircraft-level power conversion.

As a Battery Electrical Design Engineer, you will focus on the design, analysis, and integration of HV components, ensuring the electrical system is optimized for high power density, EMI/EMC compliance, and rigorous aerospace safety standards. You will be a key contributor to the Energy Storage and Power Systems (ESPS) team, driving the electrical architecture from conceptual trade studies to flight-certified hardware.

In This Role, You Will...

• Architect HV Power Systems: Define and design the high-voltage distribution architecture, including busbars, wiring harnesses, contactors, fuses, and power electronics interfaces.
• Design Battery Electrical Systems: Lead the electrical design of battery modules and packs, focusing on sensing (voltage/temperature), cell balancing circuits, and high-current interconnects.
• Design Battery Charging Systems. Lead the development of on-board and off-board charging systems, ensuring compatibility with high-power standards such as CCS, MCS and NACS.
• Execute Electrical Analysis: Perform detailed electrical modeling and simulation, including power budget analysis, voltage drop calculations, fault current modeling, and thermal-electrical co-simulation.
• Manage EMI/EMC & Shielding: Define grounding and shielding strategies to ensure system compatibility and compliance with aerospace electromagnetic interference standards (e.g., DO-160).
• Drive HV Safety & Protection: Design isolation monitoring, interlock circuits (HVIL), and circuit protection schemes to ensure operator safety and system resilience during fault conditions.
• Lead Validation & Testing: Design and oversee electrical verification plans, including high-current characterization, insulation resistance testing, and dielectric withstand (HiPot) validation.

What You Will Do

• Technical Lead for HV Systems: Serve as the subject matter expert for electrical physics, providing guidance on component selection (e.g., MOSFETs, IGBTs, contactors) and high-power PCB layouts.
• System-Level Optimization: Conduct trade studies to balance electrical efficiency against mass, volume, and thermal constraints in the propulsion string.
• Supplier Engagement: Draft technical specifications and Statements of Work (SOW) for HV components and sub-assemblies, managing technical deliverables from strategic partners.
• Failure Mode Analysis: Lead electrical Failure Mode and Effects Analysis (FMEA) to identify and mitigate risks such as short circuits, arc flashes, or insulation breakdown.
• Certification Support: Author technical reports and design descriptions to demonstrate compliance with aviation safety standards (ARP 4754,DO-311A, DO-160, ARP 4761).

Requirements

• Education: B.S., M.S., or Ph.D. in Electrical Engineering or a related field.
• Experience: 8+ years of experience in electrical design, specifically with high-voltage (> 400V) systems in aerospace, EV propulsion, or heavy transportation.
• General Electrical Mastery:
  • HV Design: Deep expertise in high-power distribution, busbar design, and creepage/clearance requirements for high-altitude environments.
  • Analysis Tools: Proficiency in SPICE (LTspice/PSpice), MATLAB/Simulink, or equivalent tools for transient and steady-state electrical simulation.
  • Sensing & Control: Experience with Battery Management System (Client) hardware, including precision voltage/current sensing and isolation circuits.
• Battery Specifics: Applied knowledge of lithium-ion cell electrical behavior, state-of-charge (SoC) estimation hardware, and cell-balancing architectures.
• Design Tools: Proficiency in ECAD tools (Altium, Mentor Graphics, or Zuken) and familiarity with MCAD (NX/SolidWorks) for harness and busbar integration.
• Regulatory Awareness: Strong familiarity with aerospace environmental and safety standards (DO-160G, DO-311A).
• Communication: Ability to distill complex electrical architectures into clear requirements for software, mechanical, and systems engineering teams.

BayOne is an Equal Opportunity Employer and does not discriminate against any employee or applicant for employment because of race, color, sex, age, religion, sexual orientation, gender identity, status as a veteran, and basis of disability or any federal, state, or local protected class.

This job posting represents the general duties and requirements necessary to perform this position and is not an exhaustive statement of all responsibilities, duties, and skills required. Management reserves the right to revise or alter this job description.