Sr Engineer, Mechanical Design – High Voltage EV Systems

Aptera Motors Corp; Carlsbad (CA); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Market-competitive compensation

Employee + dependents benefits

Job summary

Aptera Motors Corp is seeking an experienced Sr Engineer, Mechanical Design for High Voltage EV Systems to design compact, reliable enclosures and packaging for 400–800 V systems. You will collaborate with electrical and systems engineers to meet electrical, thermal and safety requirements.

The role emphasizes CAD modeling, 3D layouts, EMI/EMC considerations, and hands-on prototyping, with on-site work in California. Bachelor’s degree and 5+ years in HV packaging are preferred.

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 5+ years in mechanical packaging of high-voltage EV systems.
• Ability to read schematics and wiring diagrams.
• Experience with EMI/EMC considerations in packaging.

Responsibilities

• Package high-voltage automotive systems (400–800 V) including enclosures and packaging.
• Develop dense layouts optimizing thermal performance and dielectric strength.
• Collaborate with electrical engineers on component placement and routing.
• Incorporate EMI/EMC mitigation strategies.
• Produce 3D CAD models and 2D drawings in CATIA; learn Arcadia on the job.
• Support harness routing and packaging; participate in design reviews.
• Hands-on assembly for proving out designs and creating work instructions.

Education

Bachelor's degree in Mechanical Engineering

Tools

CATIA

Arcadia

Job description

Sr Engineer, Mechanical Design – High Voltage EV Systems

is dedicated to building a future where every journey is powered by the sun. We specialize in creating solar electric vehicles that revolutionize the way we travel, providing sustainable and efficient transportation solutions.

is built on transparency, ethical treatment of one another, a bias for action, and leading by example.

Sr Engineer, Mechanical Design – High Voltage EV Systems

About the role

We are seeking an experienced Mechanical Design Engineer with expertise in packaging high-voltage systems (400 V – 800 V) for electric vehicles. This role focuses on designing compact, reliable, and safe enclosures and packaging for circuit board assemblies, busbars, harnesses, and high-voltage components. You’ll work closely with electrical and systems engineers to ensure that mechanical packaging solutions meet demanding electrical, thermal, and safety requirements.

What you'll do

• Package high-voltage (400–800 V) automotive systems , including circuit board assemblies, busbars, harnesses, and power distribution units.


• Develop dense, compact layouts that optimize thermal performance, dielectric strength, clearances/creepage, and long‑term reliability .


• Apply a working knowledge of dielectric properties of materials, thermal management, and material creep to ensure safe, durable designs.


• Collaborate with electrical engineers on component placement, routing, and packaging trade-offs .


• Incorporate EMI/EMC mitigation strategies into packaging solutions.


• Produce detailed 3D CAD models and 2D drawings (CATIA preferred; willingness to learn required).


• Support harness routing and packaging using Arcadia (or learn quickly on the job).


• Participate in design reviews and work closely with suppliers to ensure manufacturable solutions.


• Hands on assembly of the designs for proving out design and creating work instructions.

Qualifications

• Proven track record in packaging 400–800 V EV components (circuit board assemblies, busbars, harnesses, distribution units).


• Read and understand system schematics and wiring diagrams.


• Proficiency in 3D CAD tools (CATIA preferred) with ability to deliver production‑ready models and drawings.


• Familiarity with EMI/EMC design considerations in packaging.


• Bonus: Experience with Arcadia harness design tool.

Team Structure

• Individual contributor; collaborate with other teams and individuals, as necessary

Required Experience

• 5+ years of experience in mechanical packaging of high‑voltage systems for automotive or related industries

Educational Requirements

• Bachelor’s degree (or higher) in Mechanical Engineering or related field

Salary + Benefits

• Market competitive compensation package


• Fully funded benefits package for employee + dependents