Energy Solutions Senior Mechanical Engineer

Job Description

Join our Team as an Energy Solutions Senior Mechanical Engineer!

The Role:

We're seeking a passionate and experienced Energy Storage Mechanical Engineer to lead the mechanical and thermal design, development, validation, and execution of Lithium-Ion (Li-Ion) Battery Pack and Fuel Cell energy storage system architectures and related components.

In this role, you'll be responsible for defining, designing, and documenting mechanical and thermal management systems-including components, assemblies, and sub-systems-while managing procurement, builds, and validation activities. You'll collaborate across disciplines to drive robust, scalable solutions, and help shape the future of electrified power systems.

What You'll Be Doing:

• Collaborate closely with Systems Engineering, Styling, Manufacturing Engineering, Validation/Test, and key suppliers.
• Translate system-level, regulatory, and customer requirements into detailed mechanical/thermal product specifications.
• Design mechanical systems and components that package, structurally support, thermally manage, and electrically interface Li-Ion cells/modules.
• Drive strategies that maximize design/component reuse, Design for Manufacturing (DFM), Design for Assembly (DFA), and serviceability.
• Specify key components and materials, including structures, fuses, housings, heating/cooling elements, and sealing solutions.
• Own the creation and release of 2D/3D drawing packages, perform tolerance analysis, and apply best practices in Geometric Dimensioning and Tolerancing (GD&T).
• Support or lead manufacturing process development and Design for Manufacturing Reviews.
• Act as a liaison between internal engineering teams and suppliers, ensuring clear translation of technical requirements.
• Provide input on Battery Management System (BMS) and high-voltage electrical system integration.
• Author test plans, execute lab testing, and analyze/interpret results.
• Develop design and process documentation including DFMEAs, PFDs, and PFMEAs.
• Evaluate and select suppliers based on specifications and validation data; assist in Advanced Product Quality Planning (APQP).
• Create and maintain mechanical system DVP&Rs; support overall system-level DVP&R efforts.
• Ensure parts are available for prototype builds and support validation/test events.
• Troubleshoot mechanical issues related to energy storage systems across development phases.
• Participate in continuous learning via technical conferences, industry publications, and professional networks.
• Travel anticipated to be ~10%.

What We're Looking For:

• Bachelor's degree in Mechanical, Electrical, or Systems Engineering.
• 10+ years of experience in automotive or electro-mechanical product development, with demonstrated success launching products into high-volume production.
• Strong understanding of electromechanical systems, thermal management, and mechanical design principles.
• Proficient in 3D CAD (e.g., Creo, CATIA) and able to create production-level design documentation.
• Experience with CAE tools for thermal, structural, and fluid flow analysis.
• Demonstrated experience developing Engineering Specifications, Statements of Work (SOWs), and supplier interface documents.
• Strong communicator, capable of presenting complex technical data internally and externally.
• Familiarity with industry standards and certifications including UL, IEC, EN, and ANSI.
• Experienced in validation frameworks including the System V Model.
• Skilled in structured problem solving (e.g., 8D, Shainin RedX, Six Sigma).
• Team-oriented, self-driven, strategic thinker with a high attention to detail.

What Sets You Apart:

• Hands-on experience with high-voltage Li-Ion battery packs and modules.
• Familiarity with tooling/fixturing design for concept validation and production.
• In-depth knowledge of thermal and structural analysis specific to battery enclosures.
• Background in energy storage safety and regulatory compliance.
• Experience working with both prototyping and mass production.

Where and When You'll Work:

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

What Your Total Compensation & Benefits Package will look like:

Salary - $149,500 - $177,000 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.

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