Product Design Engineer - Pouch Cell Design

Lyten; San Jose (CA); On-site; USD 106,000 - 159,000; Full time

Job summary

Lyten seeks a Product Design Engineer with strong new process introduction and productization experience to own cell mechanical design, BOMs, and complete the transition from R&D to pilot build and scaled production for high-performance pouch battery systems. The role emphasizes manufacturability and safety, with applications in UAV platforms.

The ideal candidate will combine mechanical design expertise with battery domain knowledge, participate in DFMEA/PFMEA, and collaborate with

Qualifications

• B.S./M.S in Mechanical Engineering or related field.
• 2+ years in Mechanical Design.
• Proficient in CAD design (SolidWorks preferred).
• Experience with PLM/PDM systems.
• Proficient in data analysis tools (Python, R, MATLAB, Excel).
• Knowledge of statistical process control (SPC).
• Experience working with cross-functional NPI or pilot builds in a fast-paced environment.

Responsibilities

• Own and develop cell assembly drawings with detailed specifications, CAD models, and BOMs for pouch cell builds.
• Design and optimize electrode layout, stack architecture, and mechanical containment.
• Ensure designs meet manufacturing feasibility and safety requirements for NPI/pilot build readiness.
• Participate in design reviews, DFMEA/PFMEA, and engineering change documentation.
• Identify and resolve assembly issues specific to pouch cells (tab alignment, sealing integrity, electrolyte distribution).
• Understand the process capabilities of the pilot line to reflect on the cell design.
• Develop comprehensive battery performance specifications based on business development needs and customer requirements.
• Use statistical analysis tools to identify trends and correlations in battery performance data.
• Partner with technicians and operators to identify and implement process improvement measures.
• Design and execute DOEs (Design of Experiments) on production lines with follow-through on MES systems.
• Lead tolerance stack-up analysis for battery pack assemblies and cell integration.
• Establish and validate in-process quality control methods and inspection criteria.
• Work with supply chain team on cost-reduction initiatives and value engineering.

Skills

Mechanical Design

CAD design

Data analysis

SPC knowledge

NPI/pilot builds

DFMEA/PFMEA

Education

B.S./M.S in Mechanical Engineering

Tools

SolidWorks

PLM/PDM

Job description

Lyten is leading an industrial revolution through Lyten 3D Graphene™, a breakthrough supermaterial unlocking a new generation of products — from lithium–sulfur batteries and energy storage systems to concrete admixtures, lightweight composites, and next-generation sensors that are revolutionizing industries. Together, these innovations are making a massive global improvement and driving real-world impact across energy, mobility, construction, and defense.

At Lyten, we believe the most meaningful careers begin with purpose — and with people who want to make a difference. We’re not just developing advanced supermaterials — we’re about to change the world as we know it, reshaping how energy is stored, how products are built, and how progress is made.

We’re entering an exciting growth phase, scaling production across the U.S. and Europe and expanding our team of engineers, scientists, and innovators.

We are seeking a Product Design Engineer with strong new process introduction and productization experience to own cell mechanical design, engineering drawings, and complete Bill of Materials (BOM) for next-generation pouch battery systems. This role will focus on design-for-manufacturability, ensuring smooth transition from R&D to pilot build and scaled production, with applications in high-performance UAV platforms. The ideal candidate will combine mechanical design expertise with battery domain knowledge to drive product improvements and manufacturing excellence.

Job Responsibilities

• Own and develop cell assembly drawings with detailed specifications, CAD models, and detailed BOMs for pouch cell builds.

• Design and optimize electrode layout, stack architecture, and mechanical containment.

• Ensure designs meet manufacturing feasibility and safety requirements for NPI/pilot build readiness.

• Participate in design reviews, DFMEA/PFMEA, and engineering change documentation.

• Identify and resolve assembly issues specific to pouch cells (tab alignment, sealing integrity, electrolyte distribution)

• Understand the process capabilities of the pilot line to reflect on the cell design

• Develop comprehensive battery performance specifications based on business development needs and customer requirements

• Use statistical analysis tools to identify trends and correlations in battery performance data

• Partner with technicians and operators to identify and implement process improvement measures

• Design and execute DOEs (Design of Experiments) on production lines with follow-through on MES systems

• Lead tolerance stack-up analysis for battery pack assemblies and cell integration

• Establish and validate in-process quality control methods and inspection criteria

• Work with supply chain team on cost-reduction initiatives and value engineering

Required Skills/Qualifications

• B. S/M.S in Mechanical Engineering or related fields
• 2+ years in Mechanical Design
• Proficient in CAD design (SolidWorks preferred)
• Experience with PLM/PDM systems
• Proficient in data analysis tools (Python, R, MATLAB, Excel)
• Knowledge of statistical process control (SPC)
• Experience working with cross-functional NPI or pilot builds in a fast-paced environment.

Preferred Qualifications

• 2+ years hands on experience in cell design
• Understanding of battery quality control methods (Hi-Pot, dimensional analysis, CT scans, weld testing, leak testing, etc.)
• Strong understanding of pouch cell architecture, cell electrochemistry and battery performance trade-offs

Physical Requirements

• Must be able to lift 50 lbs.
• Be able to work in a lab standing up to 8 hours each day.

Compensations Range

The expected base salary range for this position is between

$106,000.00 - $159,000.00

The level of pay within the range will depend on a variety of job-related factors that may include location, relevant prior experience and/or education, or particular skills and expertise.

Disclosures

Pay Transparency Disclosure

This compensation and benefits information is based on Lyten’s estimate as of the date of publication and may be modified in the future. We generally do not negotiate on salary once we have made an offer. The level of pay within the range will depend on a variety of job-related factors that may include location, relevant prior experience and/or education, or particular skills and expertise. New hires joining the company tend to be paid within the starting base pay range noted above, with opportunities to increase pay over time based on development of additional skills, competencies, and company-specific knowledge.

Export/ITAR Compliance Disclosure

Certain positions within Lyten, Inc. require compliance with export control laws and, as a result, all interviewed candidates will be screened pre-interview to determine their eligibility in light of export restrictions. This position requires access to technology, software and other information that is subject to governmental access control restrictions, due to export controls. Employment in this position is conditioned on the continued availability of government authorization to authorize release of such items, to the extent required, including without limitation an export license, or other documentation required to establish authorization to receive access to such items. Company may delay commencement of employment, rescind an offer of employment, terminate employment, and/or may modify job responsibilities, compensation, benefits, and/or access to Company facilities and information systems, as Company deems appropriate, in order to ensure compliance with applicable government access control restrictions.

Lyten is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, national origin, sex, age, status as a protected veteran, or status as a qualified individual with a disability. EEO Employer/Vet/Disabled.

Principals only; third party or agency submitted candidates will not be considered.

Why Work at Lyten

At Lyten, you’ll be part of a team that’s redefining what’s possible in energy, materials, and manufacturing. We’re not just imagining the future — we’re building it today with breakthrough technologies that are changing how products are made and how industries innovate.

Our people are the heart of that mission. From world-class scientists and engineers to creative problem-solvers in operations, manufacturing, and commercialization, every member of the Lyten team plays a role in turning bold ideas into real-world impact. We believe that the best work happens when you’re doing great things in the world — with people you like. Collaboration, curiosity, and a shared sense of purpose drive everything we do.

What You’ll Find at Lyten

• A mission that matters: Contribute directly to solving complex challenges in energy, mobility, and materials innovation.
• Cutting-edge innovation: Work on technologies at the intersection of materials science, energy storage, and advanced manufacturing that strengthen energy security and local supply chains.
• Extraordinary people: Join a team of talented, friendly, and down-to-earth innovators who support, challenge, and inspire one another every day.
• Teamwork and culture: Experience a workplace built on trust, respect, and shared success — where collaboration fuels breakthroughs and everyone’s ideas are heard.
• Global impact: Help scale new materials and energy solutions that reinforce industrial resilience across the U.S. and Europe.
• Career growth: Be part of a fast-moving company entering a commercial growth phase, with opportunities to lead, learn, and make your mark.
• Purpose-driven values: Thrive in an environment that celebrates ingenuity, optimism, and meaningful progress — together.

Lyten offers the opportunity to do the most important work of your career — helping build the technologies that will power the next century of innovation.

Join us, and help transform industries, communities, and the planet with friends who share your drive to make a difference.