Senior Battery Pack Design Engineer

tmhcareers; City of Rochester (NY); On-site; USD 134,000 - 171,000; Full time

Benefits offered by this job

Relocation assistance

13 paid holidays

Health, dental, vision plans

401(k) match up to 6%

Life insurance

Job summary

Toyota Material Handling North America is seeking a Senior Battery Pack Design Engineer to lead the architecture, design, validation, and launch of lithium-ion battery packs and modules for material handling equipment. You will own module and pack architectures, packaging, cooling, electrical isolation, and serviceable assemblies, coordinating with multiple engineering teams.

The role requires hands-on product development experience, strong GD&T and DFMEA skills, and the ability to drive DFMA

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field.
• 10+ years of product development experience with electromechanical systems.
• Strong understanding of battery cell technologies and pack integration.
• CAD proficiency with Creo/CATIA/NX or equivalent.

Responsibilities

• Lead mechanical design of battery modules and packs from concept to production launch.
• Own architectures including structural components, cell retention, cooling, and electrical isolation features.
• Develop CAD models, drawings, specifications, and BOMs for production.
• Conduct packaging studies and trade-off analyses for cells, modules, and supporting structures.
• Drive DFM/ DFA and serviceability throughout product development.
• Collaborate with electrical, BMS, systems, and thermal teams for integration.
• Support validation activities and root-cause investigations.

Skills

Battery design

DFM DFA

Leadership

CAD proficiency

Thermal management

APQP DFMEA

Packaging design

GD&T

HV interconnects

Education

Bachelor's degree in Mechanical Engineering

Tools

Creo

CATIA

NX

Job description

Join our Team as a Senior BATTERY PACK DESIGN ENGINEER!

The Role:

We’re seeking a passionate and dedicated Senior Battery Pack Design Engineer who brings enthusiasm and expertise to the table. In this role, you’ll lead the architecture, design, component selection, development, validation, and launch of lithium-ion battery packs and modules.

This role will play a key part in the design and development of battery systems, contributing to battery structures, module packaging, thermal management systems, electrical isolation features, safety-critical components, and enclosure assemblies from concept through production release. Working closely with cross-functional engineering, manufacturing, validation, and supplier teams, the successful candidate will help define and execute robust design solutions that meet performance, safety, reliability, manufacturability, and cost objectives.

The ideal candidate brings strong battery design expertise, systems-thinking capability, and hands-on product development and manufacturing experience, with the ability to influence technical direction and drive subsystem-level design decisions within a collaborative team environment.

We value innovative and creative ideas—yes, even during meetings (where snacks are always welcome). If you enjoy tackling challenges with positivity and a bit of humor, you’ll feel right at home here.

What You’ll Be Doing:

• Lead the mechanical design and development of battery modules and battery packs for material handling equipment from concept through production launch.
• Own battery module and pack architectures such as structural components, cell retention systems, compression mechanisms, cooling systems, electrical isolation features, busbar integration, and serviceable assemblies.
• Develop innovative solutions balancing performance, cost, mass, manufacturability, thermal performance, durability, and safety.
• Create and release production-ready CAD models, engineering drawings, specifications, and BOMs.
• Perform packaging studies and trade-off analyses for battery cells, modules, cooling systems, safety-critical components, and supporting structures.
• Drive Design for Manufacturing (DFM), Design for Assembly (DFA), and serviceability initiatives throughout the product development cycle.
• Collaborate with electrical, BMS, systems, and thermal engineering teams to ensure successful integration of mechanical and electrical subsystems.
• Support structural, thermal, vibration, shock, abuse, and environmental validation activities.
• Develop and maintain DFMEAs, DVP&Rs, Engineering Specifications, Statements of Work, and supplier technical requirements.
• Lead engineering prototype builds, design verification activities, root cause investigations, and corrective action implementation.
• Conduct tolerance stack-up analyses and apply GD&T best practices to ensure robust production designs.
• Work directly with suppliers on component development, tooling feasibility, APQP activities, and production readiness reviews.
• Support battery pack safety strategies including thermal runaway mitigation, electrical isolation, ingress protection, and compliance requirements.
• Identify technical risks early and develop mitigation plans to ensure successful program execution.
• Support manufacturing launch activities and transition designs into volume production environments.

What We’re Looking For:

• Bachelor’s degree in Mechanical Engineering or related engineering discipline.
• 10+ years of product development experience with demonstrated success launching complex electromechanical systems into production.
• Strong understanding of battery cell technologies, module architectures, pack integration, and energy storage system design.
• CAD proficiency using Creo, CATIA, NX, or equivalent 3D modeling software.
• Strong knowledge of GD&T, tolerance analysis, and engineering drawing standards.
• Experience with battery enclosure design, structural components, sealing systems, electrical isolation, and thermal management systems.
• Familiarity with manufacturing processes including castings, stampings, extrusions, sheet metal, plastics, machining, and assembly operations.
• Experience supporting prototype builds, validation testing, production launches, and supplier development activities.
• Working knowledge of CAE tools supporting thermal, structural, vibration, and durability analysis.
• Experience developing DVP&R, DFMEA, PFMEA, Engineering Specifications, and APQP deliverables.
• Strong technical communication and cross-functional leadership skills.
• Ability to work effectively in fast-paced product development environments.

What Sets You Apart:

• 5+ years of direct experience designing lithium-ion battery modules, battery packs, or high-voltage energy storage systems.
• Direct ownership of battery module or battery pack designs that successfully launched into production.
• Experience with cylindrical, prismatic, or pouch cell packaging architectures.
• Expertise in battery cooling systems including liquid, refrigerant, or air-cooled designs.
• Experience with cell compression systems, busbar integration, HV interconnects, and electrical isolation strategies.
• Knowledge of battery abuse testing, thermal runaway containment, propagation mitigation, and safety design principles.
• Experience developing systems compliant with UL, IEC, SAE, ISO, and UN38.3 requirements.
• Familiarity with battery manufacturing processes, module assembly lines, and pack production systems.
• Hands-on prototype build experience and comfort working directly with hardware in the lab and on the manufacturing floor.
• Experience supporting innovation and advanced concept development.

Where and When You’ll Work:

• This is an in-person role located at our Rochester, NY office—ideal for those who thrive in a hands-on, team-oriented environment.

What Your Total Compensation & Benefits Package will look like:

Salary-$133,605 - $171,290 per year. Compensation depends on the selected candidate’s education and experience.

Relocation: This role may be eligible for relocation assistance.

World Class Benefits:

• Competitive Salary
• Performance Bonus
• Generous Paid Time Off and 13 Paid Holidays
• Affordable Medical plans and no-cost Dental & Vision options
• 100% 401(k) match up to 6%
• Company-Paid Life Insurance, Short-Term Disability, and Long-Term Disability
• Tuition Assistance Program
• Employee Assistance Program (EAP) with access to mental health care, legal support, and financial guidance
• Recognition and Kaizen (continuous improvement) Reward Programs
• Meaningful opportunities for personal and professional development
• Best in class work culture!

Big Name | Big Opportunities | Life is Better at Toyota

Toyota Material Handling North America (TMHNA), the industry leader in forklift sales, comprises two main brands: Toyota Material Handling and The Raymond Corporation. We believe investing in the best people, products, and processes will fuel our future success, and we will always be driven by our foundational principles of “respect for people” and “continuous improvement”. With opportunities across North America, we are confident you will find the right position within TMHNA that can help you build a long, fulfilling career.

Learn more here: https://www.toyotaforklift.com/careers

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