EV Battery Pack Lead Engineer

Job Title: EV Battery Pack Lead Engineer

Location: Foster City CA

Domain: Electric Vehicles Battery Pack Engineering Energy Storage Systems

About the Role

We are looking for a highly skilled EV Battery Pack Lead Engineer to lead end to end design development validation and industrialization of high voltage battery packs for electric vehicles. This role requires strong technical depth in battery systems engineering leadership cross functional collaboration and the ability to drive design decisions that meet performance safety cost and timing targets.

Key Responsibilities

1. Battery Pack Architecture & System Design

• Lead the development of HV battery pack architecture module configuration cooling strategy HV/LV distribution and structural layout.
• Define system requirements technical specifications and Interface Control Documents (ICDs).
• Conduct trade-off studies considering cell format thermal behavior crash safety cost manufacturability and packaging constraints.

2. Detailed Design & Engineering Leadership

• Guide mechanical thermal electrical and BMS engineers throughout the design cycle.
• Review CAD models drawings GD&T DFMEA and DVP&R documentation.
• Ensure DFM/DFA best practices and compliance with industry standards (UN38.3 UL2580 ISO 26262 ISO 6469).
• Manage supplier technical interactions for cells cooling plates BMS enclosures and busbars.

3. CAE Validation & Testing

• Review CAE results (structural crashworthiness vibration thermal/CFD).
• Define and execute validation plans including DV PV abuse testing IP rating vibration shock and regulatory compliance.
• Drive correlation between CAE and physical test results.

4. Program & Stakeholder Management

• Lead technical discussions with customers suppliers and cross functional teams.
• Manage technical risks open issues ECO/ECN processes and release gates.
• Provide status updates review technical deliverables and ensure timely milestone achievements.

5. Industrialization Support

• Support prototype builds plant trials PFMEA and control plan development.
• Coordinate with manufacturing engineering for tooling fixtures assembly sequence and process validation.
• Ensure readiness for PPAP and SOP.

Required Skills & Qualifications

• Bachelors or Masters degree in Mechanical Engineering Electrical Engineering Automotive Engineering or equivalent.
• 8 years of experience in EV battery pack or energy storage system design.
• Strong knowledge of lithium ion cell technology thermal management HV safety and mechanical structures.
• Proficiency in CAD tools (CATIA V6) and PLM systems.
• Good understanding of CAE concepts and ability to interpret simulation results.
• Hands-on experience with DV/PV testing and correlation.
• Excellent problem-solving leadership and communication skills.
• Familiarity with automotive standards and regulations relevant to EV battery systems.

Preferred Qualifications (Nice to Have)

• Experience with ISO 26262 functional safety for BMS.
• Prior exposure to global EV OEMs/Tier 1s.
• Knowledge of pack manufacturing processes (welding bonding potting gasketing).
• Experience in HV/LV architecture wiring and controls.
• Agile/SAFe program management experience.

Pi-square technologies is a Michigan (USA) Headquartered Automotive Embedded Engineering Services company Synergy Partner for major OEMs and Tier 1s and their implementation partners in Automotive Embedded Product Development Projects Requirements Analysis Software Design Software Implementation Efficient Build Release Process and turnkey software V & V Services. We have more than 20 years of industry expertise with specialization in the latest cutting-edge automotive technologies such as Infotainment connected vehicles Cyber security OTA and Advanced Safety/ Body electronics.