Mechanical Engineer II

Synergia Automotive LLC; Ann Arbor (MI); On-site; USD 90,000 - 130,000; Full time

Job summary

Synergia Automotive LLC seeks a Mechanical Engineer II to lead the mechanical integration of lithium-ion battery cells, modules, and packs for high-performance applications. You will drive concept-to-production through design reviews, CAD modeling, BOMs, and robust verification testing.

The role requires ABET-accredited ME degree and at least 7 years in product development and design release, with expertise in SolidWorks, GD&T, DFMEA, and DFSS. Strong collaboration across teams is essential.

Qualifications

• Bachelor’s degree in Mechanical Engineering from an ABET-accredited institution.
• Minimum of 7 years of experience in product development and design release to production.

Responsibilities

• Lead mechanical integration for battery cells, modules, and packs across projects.
• Prepare and lead requirements reviews, test readiness reviews, and design reviews.
• Create models, drawings, BOMs, and manage revision control.
• Perform thermal, static stress, vibration, and shock analyses using SolidWorks Simulation.
• Apply GD&T to drawings and perform tolerance stack-up analyses.
• Define critical characteristics and inspection criteria for components and assemblies.
• Lead prototype development, design validation, and production validation testing.
• Drive closed-loop issue resolution and continuous improvement.

Skills

Cross-functional leadership

SolidWorks

GD&T

DFMEA

DFSS

Data analysis

Education

ABET-accredited Mechanical Engineering degree

Tools

Python

MATLAB

Excel

Job description

The Mechanical Engineer II is responsible for the design, development, release, and validation of lithium-ion battery cells, modules, and packs for customized applications across government, military, aerospace, and other high-performance market segments.

This role serves as the mechanical product lead from concept design through successful production launch and is responsible for integrating cells and electronic components into battery packs that meet application-specific requirements.

Essential Functions

• Read and comprehend instructions and follow established procedures.
• Serve as the mechanical engineering lead for battery cells, modules, and packs, including mechanical integration for specific projects.
• Prepare and lead requirements reviews, test readiness reviews, and design reviews to ensure alignment with stakeholder requirements.
• Generate innovative and detailed design concepts.
• Direct the creation of models, drawings, and bills of materials (BOMs) within a revision-controlled environment throughout development and production launch.
• Perform thermal, static stress, vibration, and shock analyses using SolidWorks Simulation software.
• Review part and assembly drawings; perform and document tolerance stack-up analyses; and apply GD&T to component and assembly drawings as required.
• Define critical characteristics and inspection criteria for incoming components, subassemblies, and final assemblies.
• Create and release assembly and functional test specifications for battery assemblies.
• Support supplier evaluation and selection, including activities related to measurement of critical characteristics both internally and at supplier locations.
• Create, maintain, and update DFMEAs and DVP&Rs as required.
• Lead prototype development, design validation, and production validation testing activities.
• Drive closed-loop issue resolution to prevent recurrence, mitigate risk, and support continuous improvement.
• Support new project bids and proposals related to cell, module, and pack concepts, including feasibility, scope of work, cost, and timeline.
• Perform work in a manner that prevents errors and omissions.
• Provide advisory support and assistance to the department manager as needed.
• Meet team targets and key performance indicators (KPIs).
• Follow all safety guidelines and operate in a safe manner.
• Ensure compliance with OSHA and company safety requirements - Refer to department specific competency matrix

Management Responsibilities

None

Education and Experience

• Bachelor’s degree in Mechanical Engineering from an ABET-accredited institution.
• Minimum of 7 years of experience in product development and design release to production.

Knowledge, Skills, and Abilities

• Proficiency in SolidWorks CAD software and simulation/analysis tools.
• Proficiency in applying GD&T (Geometric Dimensioning and Tolerancing) to component and assembly drawings and specifications.
• Practical experience designing structural components using manufacturing processes such as molding, casting, machining, and additive manufacturing.
• Experience developing DFMEAs for electrical and mechanical systems.
• Excellent communication skills (verbal, written, and presentation).
• Proficiency in Microsoft Office applications, particularly Excel.
• Experience with battery system product development.
• Experience working within a phase-gate product development process.
• Data analysis skills using tools such as Excel macros, Python, or MATLAB.
• Experience with FEA, thermal, vibration, and shock analysis.
• Experience designing products that incorporate electrical assemblies.
• Experience with Design for Six Sigma (DFSS) methodologies.

Disclaimer

This job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.