HV Battery ESS (Energy Storage System) Sr Lead Mechanical/Structural Engineer

Weight Watchers - Rochester Hills, MI

Full-time - Mid Level

Hybrid - Rochester Hills, MI

10,001+ employees

Wholesale Trade Agents and Brokers

About the position

The HV Battery ESS (Energy Storage System) Sr Lead Mechanical/Structural Engineer will play a crucial role in the integration of externally sourced energy storage systems into commercial vehicles. This position involves collaboration with suppliers and partners to ensure the mechanical design meets industry standards and vehicle requirements, focusing on the protection and efficiency of battery systems. The role is hybrid, based in Rochester Hills, MI, Lisle, IL, or San Antonio, TX, and requires strong leadership in engineering design activities.

Responsibilities

• Creation and management of the mechanical interface control document for the ESS
• Identify, understand and implement mechanical design requirements stemming from governmental, industry, and International brand standards
• Develop electrical, mechanical and thermal interfaces, and ensure package compatibility for cells and modules into HV ESS
• Design or evaluate suppliers' design of components using engineering techniques and knowledge of manufacturing process to ensure the most efficient and cost-effective design
• Work with the Vehicle Architecture team to define the ESS packaging envelopes and reconcile with internal component and cell packaging, Noise Vibration Harshness (NVH), enclosure rigidity, safety, aerodynamic, and other vehicle & pack requirements
• Optimization of the location, attachment, and retentions of cells, components and wiring within the HV battery enclosure with consideration for thermal, EMC, crash, etc.
• Review of supplier Design Failure Mode and Effect Analysis (DFMEAs) and co-development of HV ESS Functional Safety requirements and system DFMEAs
• Support mechanical & environmental portion of pack Design, Valuation, Plan and Report (DVP&R), provide input on test procedures, assess results, and suggest improvements
• Work with suppliers, our TRATON partners, and other International teams to achieve program goals on-time and with high quality
• Capture and integrate lessons learned from assembly processes into Verification, Certification, and Testing (VCT) procedures, requirements documentation, and AUROS (or equivalent) systems to drive continuous improvement and maintain high product quality standards
• Work closely with cross-functional teams including design engineering, quality assurance, supply chain, and operations to achieve project milestones and objectives effectively

Requirements

• Bachelor's degree in Engineering or Engineering Technology
• At least 8 years of experience in product design/development
• At least 1 year leading others in engineer/design activities
• OR Master's degree in Engineering or Engineering Technology with at least 6 years of experience in product design/development and at least 1 year leading others in engineer/design activities
• OR PhD in Engineering or Engineering Technology with at least 3 years of experience in product design/development and at least 1 year leading others in engineer/design activities

Nice-to-haves

• Bachelor's degree in Mechanical Engineering or a related field (Master's degree preferred)
• Proven experience in mechanical design and assembly, with a focus on battery module and pack assembly within the automotive, energy storage, or related industries
• In-depth knowledge of manufacturing processes, assembly techniques, and materials used in battery module and pack assembly
• Familiarity with regulatory requirements and standards applicable to battery assembly, including OSHA, ANSI, ISO, and other relevant safety and quality standards
• Experience in developing and implementing robust quality control procedures, including interim and EoL testing protocols for battery systems
• Proficiency in CAD software (e.g., SolidWorks, AutoCAD) for design, analysis, and documentation
• Strong analytical skills with a structured approach to problem-solving and process optimization
• Excellent communication skills and ability to collaborate effectively across diverse teams and organizational levels
• Hands-on experience working on HV lithium-ion batteries
• Familiar with design-for-serviceability concepts
• DFSS green or black-belt certification preferred
• Willingness and ability to travel/stay at supplier locations for extended periods as needed
• Automotive related engineering degree (Mechanical, Mechatronics, or related), MS preferred
• Working experience with HV Energy Storage Systems for mobile applications
• Working experience with relevant industry standards such as SAE J1939, J1772, ISO15118, ISO 26262, etc.
• Experience or familiarity with engineering tools and software, for example: CANalyzer, Matlab, Polarian, AUROS, XFMEA
• Experience or working knowledge of Siemens NX or similar 3D CAD and CAE analysis tools

Benefits

• Health insurance
• 401k retirement plan
• Paid holidays
• Flexible scheduling
• Professional development opportunities