Design Release Engineer, Battery Architecture

CelLink; San Carlos (CA); On-site; USD 110,000 - 160,000; Full time

Job summary

CelLink is seeking a DRE to design, develop, and execute flex circuit products from concept to development in San Carlos, CA. You will focus on battery interconnects, cell connections, and pack architecture to optimize EV and energy storage performance.

Responsibilities include modeling current collector assemblies, selecting termination methods for BMS/PCBA, defining requirements, building prototypes, and leading design reviews with DFMEAs and APQP documentation.

Qualifications

• Bachelor's degree in materials science, EE, ME, physics, or equivalent.
• 3–6 years owning designs from concept to production.
• Understand Li-Ion battery performance in pouch, prismatic, and cylindrical formats.
• Experience with simulation (FEA/CFD) analysis and interpretation preferred.
• Experience with cell connection manufacturing processes (laser-welding, ribbon/wire bonding, ultrasonic welding, resistance welding).
• Knowledge of mechanical, electrical, and thermal properties of conductors and insulators.
• Ability to size busbars with simulations and 1D joule heating calculations.
• Experience with electrical interfaces, joints, and connection methods.
• Knowledge of pack architecture and battery sizing.

Responsibilities

• Direct creation of 3D models and 2D drawings of current collector assemblies, battery interconnects, and voltage sense harnesses.
• Select termination options for connecting to BMS/PCBA (welded, crimped, soldered, ZIF, etc).
• Define requirements of flex circuit products based on internal, customer, and regulatory system-level requirements.
• Build prototype circuits (hands-on) and support launch activities.
• Lead design reviews and DFM analysis.
• DVP&R creation and execution to validate products along with DFMEAs and APQP documentation.
• Develop processes, designs, and material combinations to enhance CelLink's flexible circuits under various usage cases.

Skills

Battery interconnects

FEA/CFD simulation

Joule heating calculations

DFM analysis

Electrical interface design

Pack architecture knowledge

Busbar sizing

Welding processes

Project ownership

Education

Bachelor's degree in materials science/EE/ME/physics

Tools

SolidWorks

Altium

Job description

The DRE will be responsible for designing, developing, and executing flex circuit products from concept to development. The right person will have experience with battery systems, focusing on battery interconnects, cell connections, and pack architecture, to ensure optimal performance in EV and energy storage applications.

Essential Duties and Responsibilities

• Direct creation of 3D models and 2D drawings of current collector assemblies, battery interconnects, and voltage sense harnesses.
• Selecting termination options for connecting to BMS/PCBA, such as welded, crimped, soldered, ZIF, etc.
• Define requirements of flex circuit products based on internal, customer, and regulatory system-level requirements.
• Build prototype circuits (hands-on) and support launch activities.
• Lead design reviews and DFM analysis.
• DVP&R creation and execution to validate products along with DFMEAs and other pertinent APQP documentation.
• Develop processes, designs, and material combinations to enhance the performance of CelLink's flexible circuits under various usage cases and applications.

Minimum Qualifications (Education, Knowledge, Skills, and Abilities)

To perform this job successfully, the individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions.

• Bachelor's Degree in materials science, EE, ME, physics, or equivalent.
• 3-6 years of experience owning designs from concept to production.
• Understand the requirements and performance of Li-Ion batteries in all cell formats (pouch, prismatic, and cylindrical).
• Experience in simulation (FEA and CFD) analysis and interpretation is preferred.
• Experience with cell connection MFG processes such as laser-welding, ribbon/wire bonding, ultrasonic welding, resistance welding, etc.
• Knowledge of mechanical, electrical, and thermal material properties for common conductor materials, various types of plating, and insulating materials.
• Ability to size busbars using simulations and 1D joule heating calculations.
• Experience with the design and validation of electrical interfaces, joints, and connection methods.
• Knowledge of pack architecture and battery sizing (series and parallel connections, nominal energy, power, etc.).

Locations

San Carlos, CA

Salary

We’re hiring for multiple positions and will align compensation accordingly based on level and years of experience.

Physical Demands and Work Environment

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform the functions.

Working Conditions/Hours

Salaried Exempt

Physical Demands – Office and Manufacturing Environment

While performing the duties of this position, the employee is regularly required to talk or hear. The employee frequently is required to use hands or fingers, handle, or feel objects, tools, or controls. The employee is required to stand; walk; sit; reach with hands and arms pull/push; climb or balance; and stoop, kneel, crouch, or crawl. The employee must lift and/or move up to 50 pounds without assistance. Specific vision abilities required by this position include close vision, distance vision, color vision, peripheral vision, and the ability to adjust focus.

Work Environment –

Includes both a typical office environment, with minimal exposure to excessive noise or adverse environmental issues, and a shop environment, with exposure to high noise levels from operating machines, physical hazards from moving equipment and machine parts, nuisance dust, and skin exposure to chemicals used to run/maintain machines.

PPE-

May be required to wear Personal Protective Equipment, including but not limited to safety glasses, safety shoes, bump-caps, gloves, hair nets, masks, & clean-room frocks while adhering to the prescribed safety procedures.

CelLink CA Privacy Policy

We believe diversity and inclusion among our teammates are essential to our success. We celebrate diversity and are committed to creating an inclusive environment for all employees while building teams that represent a variety of backgrounds, perspectives, and skills. We are an equal opportunity employer. All employment is decided based on qualifications, merit, and business needs. CelLink participates in the E-Verify program in specific locations as required by law.

CelLink was founded in 2012 and entered volume production in 2018. CelLink provides electrical systems to the world’s leading automotive OEMs & EV manufacturers, data center developers, and stationary power companies. The company has raised approximately $315M in funding through private investment and multiple grants from the US Department of Energy. CelLink’s investors include 3M, Atreides, BMW, BorgWarner, Bosch, D1 Capital, Fidelity, Fontinalis Partners, Ford, Franklin Templeton, Lear, Park West, SK Telecom, Standard Investments, T. Rowe Price, Tinicum, and Whale Rock