Battery Pack Mechanical Design Engineer II, Amazon Prime Air Electric Propulsion Subsystem

We are seeking a Battery Pack Mechanical Hardware Development Engineer II to join our Drone Electric Propulsion Subsystem (EPS) this role you will be a significant and autonomous contributor solving difficult hardware engineering problems related to battery systems. You will design develop and validate battery packs from concept through production working on high-voltage battery systems that push the boundaries of performance reliability efficiency and safety.

This position requires an engineer who demonstrates strong technical depth in battery pack design while also exhibiting the system-level thinking and influence characteristic of our most impactful contributors.

Key job responsibilities
Design & Development:
Design mechanical architecture for high-voltage Li-Ion battery packs including cell arrangement modules enclosures structural supports and interconnections.
Create detailed 3D models and manufacturing drawings using CATIA with GD&T.
Develop cell-to-module and module-to-pack packaging concepts balancing energy density safety and manufacturability.
Design and integrate thermal management systems and sealed IP-rated enclosures.
Analysis & Validation
Perform FEA (structural vibration thermal) and tolerance stack-up analysis to validate designs.
Plan and execute prototype builds validation testing and root-cause failure analysis.
Safety & Compliance
Design to high-voltage safety requirements including creepage/clearance isolation and HVIL.
Incorporate thermal runaway mitigation and ensure compliance with applicable standards (UN 38.3 UL 2580 IEC 62133 etc.).
Develop verification test plans to verify designs against DO-160 and DO-274 standards
Support DFMEA and design-for-safety activities.
Cross-Functional Collaboration
Partner with electrical BMS systems and safety engineers on mechanical and interface requirements.
Coordinate with manufacturing supply chain and suppliers on DFM/DFA tooling and sourcing.
Participate in and present at design reviews.
Documentation & Process
Maintain engineering documentation and manage changes through PLM.
Support project planning with estimates timelines and risk assessments.
Continuous Improvement
Identify opportunities to improve cost weight safety and manufacturability.
Contribute to team design standards and best practices.


- Bachelors degree in mechanical engineering or equivalent
- 4 years of working in mechanical engineering or equivalent experience
- Demonstrated experience taking a mechanical design from concept through prototype to production.
- Battery pack mechanical design: cell-to-pack architecture module design cell holders busbar integration enclosures and structural support for prismatic cylindrical or pouch cells.
- CAD proficiency: SolidWorks Creo CATIA or NX for 3D modeling GD&T and detailed drawings.
- Sealing and enclosure design: IP-rated enclosures gaskets potting/encapsulation and pressure equalization/venting.
- Understanding of high-voltage safety practices creepage and clearance requirements and isolation/insulation coordination.
- Familiarity with thermal runaway mitigation and propagation prevention (venting barriers intumescent materials).
- Interface knowledge with the BMS (Battery Management System) contactors fuses HVIL (high-voltage interlock loop) and service disconnects.
- Awareness of cell chemistry behavior and how it drives mechanical/thermal requirements.
- DFM/DFA (design for manufacturing and assembly) and experience with joining methods relevant to packs (laser/ultrasonic/resistance welding adhesives fastening).
- Tolerance analysis and experience working with suppliers on tooling injection molding sheet metal die casting or extrusions.
- Prototyping bring-up and validation testing (environmental chambers vibration tables HALT/HASS).
- DFMEA and design-for-safety methodology.
- Familiarity with PLM systems and engineering change management.
- Soft Skills & Cross-Functional Collaboration
- Strong collaboration with electrical BMS/firmware systems safety and manufacturing teams.
- Requirements definition design reviews and clear technical documentation.
- Root-cause analysis and structured problem solving (8D DMAIC fishbone).

- Masters degree in mechanical engineering or equivalent
- 3 years of working in mechanical engineering or equivalent experience
- Thermal management: designing cooling systems (liquid cold plates air cooling phase-change or immersion) thermal interface materials and managing heat generation/dissipation across the pack.
- Structural/mechanical analysis: FEA for stress vibration shock and drop; tolerance stack-up analysis.
- Experience in automotive aerospace marine or grid-storage battery systems.
- Scripting/simulation tools (MATLAB Python) for design automation or thermal modeling.
- Experience with fast-charge thermal design and high-C-rate applications.

Amazon is an equal opportunity employer and does not discriminate on the basis of protected veteran status disability or other legally protected status.

Our inclusive culture empowers Amazonians to deliver the best results for our customers. If you have a disability and need a workplace accommodation or adjustment during the application and hiring process including support for the interview or onboarding process please visit for more information. If the country/region youre applying in isnt listed please contact your Recruiting Partner.

The base salary range for this position is listed below. Your Amazon package will include sign-on payments and restricted stock units (RSUs). Final compensation will be determined based on factors including experience qualifications and location. Amazon also offers comprehensive benefits including health insurance (medical dental vision prescription Basic Life & AD&D insurance and option for Supplemental life plans EAP Mental Health Support Medical Advice Line Flexible Spending Accounts Adoption and Surrogacy Reimbursement coverage) 401(k) matching paid time off and parental leave. Learn more about our benefits at WA Seattle - 117300.00 - 160000.00 USD annually