Senior Design Engineer

Acculon Energy; Columbus (OH); On-site; USD 120,000 - 180,000; Full time

Job summary

Acculon Energy in Columbus, OH is seeking a Senior Products Design Engineer to own the full lifecycle of battery pack systems from concept through production launch. You will guide requirements, drive DFMEA/PFMEA, and lead cross-functional teams on design, validation, and supplier engagement.

This role requires hands-on prototype work, mentoring, and strong communication with customers and leadership to ensure programs stay on track.

Qualifications

• 7+ years of progressive experience in product design, mechanical or electrical engineering, with ownership of battery pack/energy storage programs.
• Led complex engineering programs independently and mentored junior engineers.

Responsibilities

• Guide transformation of complex requirements into actionable technical specs for customers and leadership.
• Own DFMEA end-to-end and partner on PFMEA with manufacturing, mentoring others in FMEA methodology.
• Lead concept design and technical proposals for complex product programs and drive detailed design.
• Drive pack assembly, sub-components, enclosure structures, and 2D drawings.
• Design LV/HV interconnects and wire harness routings for high-risk applications.
• Define system electrical architecture and select non-PCBA hardware components.
• Review PCBA 3D models and integration into mechanical design; manage multi-level BOM lifecycle.
• Approve ECOs for mechanical changes and coordinate with software teams.
• Support BMS software development and review release documentation.
• Review DVP&R and guide lab testing strategies for high-risk validation.
• Lead RCA investigations and drive corrective actions to closure.
• Oversee prototype integration, alpha/beta builds, and DFM reviews.
• Support prototype inventory, material ordering, and manufacturing build orders.
• Facilitate Design Reviews and DFM evaluations; close action items.
• Own product design schedule tracking and communication with customers.
• Lead supplier evaluation/qualification and manage component cost targets.

Skills

Product design leadership

Mentoring engineers

Cross-functional leadership

Technical communication

Root cause analysis

Problem solving

Tools

SolidWorks

GD&T

2D drawing standards

Schematic capture

Wire harness design

BOM management

ECO/PLM processes

BMS knowledge

ERP/MRP (Odoo)

Job description

Acculon Energy is building out a newly established Products Design section to own the full engineering lifecycle of our battery pack systems, from initial requirements through production launch. As a Senior Products Design Engineer, you will take ownership of the most complex design, reliability, and program challenges across mechanical, electrical, and systems disciplines, setting technical direction and mentoring junior and mid-level engineers. You will represent engineering directly to customers and leadership, drive design decisions from concept through DFMEA, verification, and prototype build, and ensure the documentation and change control rigor that keeps our most critical programs on track. This is a senior individual-contributor role for an engineer who thrives on ownership, ambiguity, and cross-functional leadership.

KEY RESPONSIBILITIES

• Guide definition, scoping, and translation of complex customer and internal engineering requirements into clear, actionable technical specifications, representing engineering in customer-facing requirements discussions.
• Own the review of product specifications (PRD), proactively identifying and driving resolution of the highest-risk technical ambiguities and design constraints before they impact the program.
• Own Design Failure Mode and Effects Analysis (DFMEA) end-to-end and lead cross-functional collaboration with manufacturing on Process FMEA (PFMEA), mentoring junior and mid-level engineers in FMEA methodology.
• Architect concept designs and technical project proposals for complex product programs, and lead detailed product design concept development.
• Lead the design of pack assemblies, sub-components, and enclosure structures, and generate detailed 2D manufacturing drawings.
• Own the design of low-voltage (LV) and high-voltage (HV) interconnect systems and wire harness routings for complex, high-risk applications.
• Define total system electrical architecture and make final decisions on non-PCBA/harness electrical hardware component selection.
• Own the review of PCBA 3D models and their integration into mechanical product design
• Own the structure, release, and lifecycle management of the multi-level engineering Bill of Materials (BOM) across programs.
• Drive and approve Engineering Change Orders (ECOs) for mechanical hardware modifications, and lead coordination with software teams on related updates.
• Support BMS software development and review software release package documentation.
• Review Design Verification Plans & Reports (DVP&R), and support internal/external lab testing strategy for the most complex or highest-risk validation programs.
• Lead technical Root Cause Analysis (RCA) investigations for component or pack failure modes during validation, driving corrective action plans to closure.
• Lead prototype integration and alpha/beta build execution, and drive DFM reviews across the program.
• Support prototype inventory monitoring, material ordering, and manufacturing build order issuance, escalating and resolving supply constraints.
• Facilitate formal Design Reviews and Design for Manufacturability (DFM) evaluations across components, driving the team’s action items to closure.
• Own product design schedule tracking, lead technical communications with customers, and drive resolution of issues on the tracking charts.
• Lead technical supplier evaluation/qualification and own component cost targets against the product budget, negotiating trade-offs with suppliers and program leadership.

QUALIFICATIONS

Education & Experience

• 7+ years of progressive experience in product design, mechanical engineering, or electrical engineering, including demonstrated ownership of battery pack, energy storage, electromechanical, or automotive systems programs from concept through production.
• Track record of leading complex engineering programs independently and mentoring junior and mid-level engineers.

Technical Skills

• Expert-level proficiency with 3D CAD software (SolidWorks or equivalent), GD&T, and 2D manufacturing drawing standards.
• Deep expertise in DFMEA/PFMEA methodology, DVP&R development, and root cause analysis frameworks (e.g., 8D, 5-Why, Fishbone), including experience training others.
• Proven experience owning electrical schematic capture, single-line diagrams, and low-voltage/high-voltage wire harness design.
• Strong command of multi-level BOM structuring, ECO/PLM processes, and engineering configuration management at the program level.
• Working knowledge of battery management systems (BMS), including SOC/SOH estimation and thermal management logic.
• Experience with ERP/MRP systems (Odoo preferred) for manufacturing order issuance and inventory management.

Additional Qualifications

• Excellent written and verbal communication skills, with demonstrated experience representing engineering directly to customers and leadership.
• Proven ability to lead multiple concurrent, complex programs and make sound technical decisions under ambiguity.
• Comfortable mentoring junior and mid-level engineers and helping set technical direction for the Products Design section.
• Willingness to be hands-on with prototype builds, lab testing, and Design for Manufacturability (DFM) reviews on the shop floor as needed.

WORK ENVIRONMENT & PHYSICAL REQUIREMENTS

• This role is based onsite at Acculon Energy's Columbus, Ohio facility.
• Regular presence in engineering lab and manufacturing environments is required; must be able to safely wear required personal protective equipment (PPE).
• Occasionally required to lift/move components, fixtures, or test equipment up to 50 lbs.
• Periodic travel to supplier or customer sites is expected.

EQUAL OPPORTUNITY EMPLOYER

Acculon Energy is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, veteran status, or any other legally protected characteristic.