EV Battery Pack Lead Engineer

Pi Square Technologies; Foster City (CA); On-site; USD 120,000 - 150,000; Full time

Job summary

A leading technology firm is seeking an experienced EV Battery Pack Lead Engineer in Foster City, California. This leadership role involves driving the development of high-voltage battery packs for electric vehicles. Candidates should have 8+ years of experience in EV battery systems, a strong understanding of Li-ion technology, and leadership skills. Knowledge of industry standards and processes is critical. The role emphasizes cross-functional collaboration and timely delivery of engineering milestones.

Qualifications

• 8+ years of experience in EV battery pack or energy storage systems.
• Hands-on experience with DV/PV testing and validation.
• Experience with ISO 26262 (Functional Safety).
• Knowledge of battery manufacturing processes.

Responsibilities

• Drive end-to-end development of high-voltage battery packs.
• Lead HV battery pack architecture design.
• Guide teams across mechanical, electrical, and thermal domains.
• Drive technical discussions with customers and cross-functional teams.

Skills

Expertise in Li-ion battery systems

Strong leadership

Problem-solving skills

Communication skills

Education

Bachelor’s/Master’s in Mechanical, Electrical, Automotive Engineering

Tools

CATIA V6

PLM tools

Job description

🔋 Domain: Electric Vehicles | Battery Pack Engineering | Energy Storage Systems

🔍 About the Role

We are looking for an experienced EV Battery Pack Lead Engineer to drive end-to-end development of high‑voltage battery packs for next‑generation electric vehicles. This is a leadership role requiring deep expertise in battery systems, cross‑functional engineering, and product lifecycle management, ensuring performance, safety, cost, and timeline targets are met.

Battery Pack Architecture & System Design

• Lead HV battery pack architecture including module design, cooling strategy, HV/LV distribution, and structural layout
• Define system requirements, specifications, and ICDs
• Perform trade‑off studies (cell selection, thermal, crash, cost, manufacturability)

Design & Engineering Leadership

• Guide teams across mechanical, electrical, thermal, and BMS domains
• Review CAD models, GD&T, DFMEA, and DVP&R
• Ensure compliance with UN38.3, UL2580, ISO 26262, ISO 6469

CAE, Validation & Testing

• Review CAE simulations (thermal, structural, crash, vibration)
• Define and execute DV/PV validation plans
• Lead testing & correlation between simulation and physical results

Program & Stakeholder Management

• Drive technical discussions with customers and cross‑functional teams
• Manage risks, ECO/ECN, and release milestones
• Ensure on‑time delivery of engineering milestones
• Support prototype builds, plant trials, PFMEA, and control plans
• Coordinate with manufacturing for tooling, assembly, and process validation
• Ensure readiness for PPAP and SOP

✅ Required Qualifications

• Bachelor’s/Master’s in Mechanical, Electrical, Automotive Engineering, or related
• 8+ years of experience in EV battery pack or energy storage systems
• Strong expertise in Li‑ion battery systems, thermal management, HV safety
• Experience with CATIA V6 and PLM tools
• Hands‑on experience with DV/PV testing and validation
• Strong leadership, problem‑solving, and communication skills
• Experience with ISO 26262 (Functional Safety)
• Background working with EV OEMs / Tier‑1 suppliers
• Knowledge of battery manufacturing processes (welding, bonding, potting)
• Experience in HV/LV architecture and wiring systems