EV Battery Pack Lead Engineer | Contract | Bay Area, California
EV Battery Pack Lead Engineer
Location: Bay Area, California (Onsite)
Job Type: Contract
Experience: 8 15 Years
Job Summary
We are seeking an experienced EV Battery Pack Lead Engineer to lead the design, development, validation, and industrialization of high-voltage battery packs for electric vehicles. The ideal candidate will have strong expertise in battery pack architecture, mechanical and thermal design, high-voltage systems, validation testing, and automotive product development.
The candidate will collaborate with cross-functional engineering teams, suppliers, and manufacturing stakeholders to deliver safe, reliable, cost-effective, and manufacturable battery pack solutions.
Key Responsibilities
Lead high-voltage battery pack architecture, module configuration, cooling strategy, structural layout, and HV/LV distribution.
Define system requirements, technical specifications, and interface control documents (ICDs).
Conduct engineering trade-off studies covering cell selection, thermal performance, crash safety, packaging, cost, and manufacturability.
Review CAD models, engineering drawings, GD&T, DFMEA, and DVP&R documentation.
Coordinate mechanical, electrical, thermal, and Battery Management System (BMS) engineering activities.
Review structural, crashworthiness, vibration, and thermal/CFD simulation results.
Develop and execute design validation and process validation plans, including vibration, shock, ingress protection, and battery abuse testing.
Drive correlation between CAE simulations and physical test results.
Manage technical risks, design changes, engineering change orders, release milestones, and supplier deliverables.
Support prototype builds, manufacturing trials, PFMEA, control plans, PPAP, and Start of Production (SOP).
Required Qualifications
Bachelor's or Master's degree in Mechanical, Electrical, Automotive Engineering, or a related discipline.
8+ years of experience in EV battery pack design, battery systems engineering, or related energy storage system development.
Strong understanding of lithium-ion battery technology, thermal management, high-voltage safety, and battery pack mechanical structures.
Proficiency in CATIA V6 and familiarity with PLM systems.
Experience interpreting CAE simulation results, including structural and thermal analysis.
Hands-on experience with DV/PV testing, DVP&R, and validation correlation.
Knowledge of automotive engineering standards and battery safety requirements, including UN 38.3, UL 2580, ISO 26262, and ISO 6469.
Experience with DFMEA, DFM/DFA, engineering change management, and manufacturing readiness.
Strong technical leadership, problem-solving, communication, and cross-functional collaboration skills.
Preferred Experience
Experience leading battery pack development from architecture through production launch.
Experience coordinating with battery cell, BMS, cooling system, enclosure, and busbar suppliers.
Familiarity with prototype builds, process validation, PPAP, and SOP readiness.
Ideal Candidate: A hands-on battery pack engineering leader with strong CATIA V6 expertise and proven experience in EV battery pack design, validation, and industrialization.
