EV Battery Pack Lead Engineer

Katalyst-Healthcares-; San Francisco (CA); On-site; USD 150,000 - 230,000; Full time

Job summary

Katalyst-Healthcares- is seeking an EV Battery Pack Lead Engineer in San Francisco to lead end‑to‑end design, validation, and industrialization of high‑voltage battery packs for electric vehicles.

You will guide mechanical, thermal, electrical, and Client engineers through the design cycle, review CAD/DV/DFMEA, and ensure compliance with UN38.3, ISO 26262, and ISO 6469, while driving supplier interactions and DFM/DFA best practices.

Qualifications

• 8+ years of EV battery pack or energy storage system design experience.
• Strong knowledge of lithium‑ion cell technology, thermal management, HV safety, and mechanical structures.
• Familiarity with automotive standards and regulations relevant to EV battery systems.
• Proficient in CAD tools and DV/PV testing with ability to interpret results and drive actions.

Responsibilities

• Lead HV battery pack architecture, module configuration, cooling strategy, HV/LV distribution, and structural layout.
• Guide mechanical, thermal, electrical, and other engineers through the design cycle and review CAD/GD&T/DVPR documentation.
• Review CAE results and define execution plans for validation and testing, ensuring correlation with physical tests.
• Manage technical risks, ECO/ECN processes, and release gates while coordinating with suppliers.
• Coordinate with manufacturing for tooling, fixtures, and process validation to ensure PPAP readiness.

Skills

Leadership

Cross-functional collaboration

DV/PV testing

Problem solving

Communication

Education

Bachelor's or Master’s in Mechanical/Electrical/Automotive Engineering

Tools

CATIA V6

PLM systems

Job description

Job Description:

We are looking for a highly skilled EV Battery Pack Lead Engineer to lead end‑to‑end design, development, validation, and industrialization of high‑voltage battery packs for electric vehicles. This role requires strong technical depth in battery systems, engineering leadership, cross‑functional collaboration, and the ability to drive design decisions that meet performance, safety, cost, and timing targets.

Key Responsibilities:

Battery Pack Architecture & System Design:

• Lead the development of HV battery pack architecture, module configuration, cooling strategy, HV/LV distribution, and structural layout.
• Define system requirements, technical specifications, and Interface Control Documents (ICDs).
• Conduct trade-off studies considering cell format, thermal behavior, crash safety, cost, manufacturability, and packaging constraints.

2Detailed Design & Engineering Leadership:

• Guide mechanical, thermal, electrical, and Client engineers throughout the design cycle.
• Review CAD models, drawings, GD&T, DFMEA, and DVP&R documentation.
• Ensure DFM/DFA best practices and compliance with industry standards (UN38.3, UL2580, ISO 26262, ISO 6469).
• Manage supplier technical interactions for cells, cooling plates, Client, enclosures, and busbars.

CAE, Validation & Testing:

• Review CAE results (structural, crashworthiness, vibration, thermal/CFD).
• Define and execute validation plans including DV, PV, abuse testing, IP rating, vibration, shock, and regulatory compliance.
• Drive correlation between CAE and physical test results.

Program & Stakeholder Management:

• Lead technical discussions with customers, suppliers, and cross‑functional teams.
• Manage technical risks, open issues, ECO/ECN processes, and release gates.
• Provide status updates, review technical deliverables, and ensure timely milestone achievements.

Industrialization Support:

• Support prototype builds, plant trials, PFMEA, and control plan development.
• Coordinate with manufacturing engineering for tooling, fixtures, assembly sequence, and process validation.
• Ensure readiness for PPAP and SOP.

Required Skills & Qualifications:

• Bachelor's or master's degree in mechanical engineering, Electrical Engineering, Automotive Engineering, or equivalent.
• 8+ years of experience in EV battery pack or energy storage system design.
• Strong knowledge of lithium‑ion cell technology, thermal management, HV safety, and mechanical structures.
• Proficiency in CAD tools (CATIA V6) and PLM systems.
• Good understanding of CAE concepts and ability to interpret simulation results.
• Hands‑on experience with DV/PV testing and correlation.
• Excellent problem‑solving, leadership, and communication skills.
• Familiarity with automotive standards and regulations relevant to EV battery systems.