EV Battery Pack Lead Engineer

S-Solutions Inc- a SyeDyn Company; San Francisco (CA); On-site; USD 180,000 - 240,000; Full time

Job summary

S-Solutions Inc- a SyeDyn Company in San Francisco seeks an experienced EV Battery Pack Lead Engineer to drive end‑to‑end design, validation, and industrialization of high‑voltage battery packs for electric vehicles.

You will lead cross‑functional teams across mechanical, thermal, electrical, and software areas, define system requirements, supervise testing campaigns, and ensure solutions meet safety, cost, and timing targets.

Qualifications

• Bachelor’s or Master’s degree in Mechanical, Electrical, Automotive Engineering or equivalent.
• 8+ years 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 interpretation of simulations.
• Hands-on DV/PV testing experience and result correlation.
• Excellent problem-solving, leadership, and communication skills.
• Familiarity with automotive standards for EV battery systems.

Responsibilities

• Lead HV battery pack architecture, module configuration, cooling, HV/LV distribution, and structural layout.
• Define system requirements, specifications, and ICDs.
• Guide mechanical, thermal, electrical, and BMS engineers through the design cycle.
• Coordinate with suppliers and manufacturing for tooling, validation, and PPAP readiness.

Skills

Leadership

Cross-functional collaboration

Problem solving

Communication

DV/PV testing

CAD

CAE concepts

Battery technology

Education

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

Tools

CATIA V6

PLM systems

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

1. 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.

2. Detailed Design & Engineering Leadership

• Guide mechanical, thermal, electrical, and BMS 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, BMS, enclosures, and busbars.

3. 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.

4. 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.
• 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.