Sr. Mechanical Design Engineer Battery & Power Electronics

Sr. Mechanical Design Engineer – Battery & Power Electronics

Position Description:

The Senior Mechanical Design Engineer will be responsible for the design and development of various battery pack and power electronics applications in support of FEV's e-mobility projects. These projects will include elements of mechanical, electrical and/or thermal components as well as complete battery pack assembly. The right candidate will support the mechanical design of these systems from concept initiation through production release

Job Responsibilities:

• Lead project activities in mechanical and/or thermal design in battery pack and power electronics engineering for e-mobility applications.
  • Mechanical packaging for various cell formats (cylindrical, prismatic, pouch)
  • Mechanical packaging for various pack components (modules, busbars, wiring, connectors, control modules, cold plates, cooling hoses)
  • Mechanical design and vehicle integration of power electronic enclosures and or thermal systems including implementation of sealing and venting strategies.
• Perform design activities such as
  • Module design and development (cell mounting, spacing, connecting, cooling)
  • Mechanical / structural design (durability, crash, light weighting)
  • Integration of electrical systems and components (fuses, contactors, wiring)
  • Cooling system design for thermal management
  • Production release and development cycle experience
  • Interface with suppliers to execute supplier quality processes such as PPAP
  • BOM management / reporting
  • Change management
  • Documentation and report creation
• Create 2D drawings based on parametric CAD models per ANSI and ISO standards
  • Datum strategies, Geometric Dimensioning & Tolerance (GD&T), Stack up Analysis, Design for Manufacturing and Design for Assembly.
• Work closely with and lead cross functional team members (vehicle, modeling and simulation, software, functional safety)
• Communicate project progress to leadership and manage project risk
• Prepare for and participate in formal and informal design review activities
• Coordinate design activities with global partners

Required Qualifications:

• BSME
• 5 years minimum experience in mechanical, electrical and/or thermal products for production applications
• Knowledge in engineering materials. Should have good understanding of different materials and grades
• Strong interpersonal skills
• Fundamental understanding of mechanical simulation techniques and processes
• Advanced knowledge of manufacturing processes
• Experience following a product development process
• DVP development and reporting
• DFMEA / Risk analysis development
• Excellent written, verbal and presentation skills in English
• Basic knowledge in automotive certification standards (UN, UL, IPC, SAE, ISO and FMVSS) and design for manufacturability.
• Basic power electronic and EV systems and architecture knowledge (DC/DC, Inverters, Batteries Chargers etc.…)
• Proficient in 2D drawing and 3D CAD creation and release on commercial platforms namely CREO, NX and CATIA.
  • Must have hands on design skills in using the CAD to route wire harnesses, sheet metal parts, plastic components, and machined components
  • Experience with Siemens Team Center or other PLM

Preferred Qualifications:

• 5 years' experience in Battery Pack design for e-mobility applications with expert power electronic and EV systems and architecture knowledge
• Understanding of cell chemistry (LTO, NMC, NCA, LFP), performance and testing
• Background in modeling, simulation, and analysis (i.e., durability, thermal, electrical)
• Understanding of electrical, thermal, and mechanical characteristics of cells, modules and/or packs (SOC, SOH, DOD life cycle etc.)
• Background in prototype builds and component validation
• Working experience in the design of injection molded engineering plastics, seals, machining, diecast aluminum, and stamped metal parts
• Engineering Master's degree
• Experience working for an OEM or Tier-1 supplier
• Familiarity with Advanced product quality planning (APQP)

Physical Demands:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
Regularly required to use hands to finger, handle, or feel objects, tools, or controls and reach with hands and arms. The employee frequently is required to stand, walk, sit, and talk or hear. The employee is occasionally required to stoop, kneel, crouch, or crawl. Must occasionally lift and/or move more than 5-10 pounds. Specific vision abilities required by this job include close vision, distance vision, depth perception, and the ability to adjust focus. The noise level in the work environment is usually moderate.

Company Overview:

FEV is a globally leading engineering and digital mobility company. Together with our customers, we are shaping the future of the mobility sector for carbon-neutral and efficient, connected, and safe transportation. Through our in-depth expertise we provide customers and society with cutting-edge solutions for the highest value of mobility and the most advanced transport experience from A to B. Our expertise includes intelligent software and sustainable propulsion system development, as well as full vehicle engineering. Additionally, our range of services includes sophisticated systems engineering, cyber physical system development, software- and E/E-integration for software defined vehicles with highly automated and safe driving functionalities as well as vehicle integration. FEV's engineering capabilities span the entire mobility ecosystem including all on-road applications as well as rail, marine, aerospace, agriculture, construction, mining, and industrial applications. Additionally, we transfer our elaborate know-how and innovations to adjacent markets, such as the energy sector, to deliver best-in-class industry solutions.
The FEV Group currently employs 7,000 highly qualified specialists in customer-oriented development centers at more than 40 locations on five continents.
Headquartered in Auburn Hills, MI, FEV North America, Inc. employs more than 500 highly skilled specialists. For more about FEV please visit our website at www.fev.com

EOE M/F/Disability/Vet