Principal Engineer - Manufacturing - Battery Pack Systems

The Manufacturing Principal Engineer will provide technical leadership for the industrialisation, manufacture, and continuous improvement of advanced battery pack systems ranging from 60V to 800V using cylindrical and pouch cell technologies. Working within a fast-paced start-up environment, the role will be instrumental in establishing a new battery pack manufacturing facility from the ground up, supporting the transition from prototype builds through to repeatable low‑to‑medium volume production for marine, industrial, and automotive applications. The role combines hands‑on engineering expertise with strategic manufacturing leadership and will drive manufacturing process development, production readiness, tooling and equipment specification, manufacturing problem solving, quality improvement, and operational scalability. The Manufacturing Principal Engineer will act as a senior technical authority within the manufacturing organisation and work closely with design engineering, operations, quality, supply chain, and leadership teams.

Key Responsibilities

• Lead the development and implementation of manufacturing processes for battery pack assembly and production.
• Provide technical leadership for prototype, pilot, and production manufacturing activities.
• Define scalable manufacturing strategies suitable for low-volume/high-mix battery pack production.
• Support establishment and optimisation of manufacturing workflows, facility layout, and production processes.
• Act as the manufacturing technical lead for industrialisation and production readiness activities.

Facility Setup & Industrialisation

• Support the setup and commissioning of a new battery pack manufacturing facility from concept through operational readiness.
• Specify and implement production equipment, tooling, fixtures, workstations, and test systems.
• Define process flows, material handling strategies, and production control methodologies.
• Develop and implement manufacturing standards, SOPs, PFMEAs, control plans, and process documentation.
• Support capacity planning and future manufacturing scalability initiatives.

Battery Pack Manufacturing & Process Development

• Lead manufacturing process development for cylindrical and pouch cell battery pack assembly.
• Support development of manufacturing techniques including:
• Cell preparation and handling
• Busbar and interconnect joining
• Laser/resistance/ultrasonic welding
• Adhesive and thermal interface application
• HV assembly and insulation
• Cooling system integration
• BMS integration
• Electrical testing and validation
• Collaborate with design engineering teams to drive DFM/DFA improvements.
• Ensure robust traceability systems are implemented across production processes.
• Provide senior-level troubleshooting support for manufacturing and production issues.
• Lead root cause analysis and corrective action activities for quality and process issues.
• Drive continuous improvement initiatives focused on quality, throughput, safety, and cost reduction.
• Support production ramp‑up activities and process optimisation.
• Analyse manufacturing data and KPIs to identify improvement opportunities.

Quality, Safety & Compliance

• Ensure manufacturing processes comply with applicable quality and safety standards.
• Support implementation of quality management systems and production quality controls.
• Ensure compliance with HV safety procedures and lithium‑ion battery handling requirements.
• Support product compliance activities including UN38.3, CE/UKCA, marine approvals, and customer‑specific standards.
• Participate in design reviews, process audits, and manufacturing risk assessments.

Cross‑Functional Collaboration

• Work closely with engineering, quality, programme management, and supply chain teams.
• Support supplier technical reviews and manufacturing readiness assessments.
• Provide technical mentorship and guidance to manufacturing engineers, technicians, and operators.
• Support customer technical discussions related to manufacturing capability and production readiness.

Qualifications, Experience and Skills Required

• Degree qualified in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, Automotive Engineering, or related discipline.
• Minimum 7–10 years’ experience in manufacturing engineering or production engineering roles within battery systems, automotive, aerospace, electrification, motorsport, marine, or related industries.
• Proven experience developing manufacturing processes for electro‑mechanical or battery‑based products.
• Strong knowledge of lithium‑ion battery pack manufacturing and assembly methods.
• Experience working with high‑voltage electrical systems and associated safety requirements.
• Demonstrated experience supporting prototype through production industrialisation activities.
• Strong understanding of manufacturing process validation and production readiness.
• Experience developing manufacturing documentation including SOPs, PFMEAs, process flows, and control plans.
• Strong root cause analysis and structured problem‑solving skills.
• Experience with Lean Manufacturing and continuous improvement methodologies.
• Excellent communication and cross‑functional collaboration skills.

Qualifications, Experience and Skills Preferred

• Experience manufacturing battery packs using cylindrical and pouch cell technologies.
• Experience in low‑volume/high‑mix manufacturing environments.
• Experience in marine, industrial vehicle, motorsport, specialist automotive, defence, or aerospace sectors.
• Knowledge of automated and semi‑automated assembly systems.
• Experience with laser welding, ultrasonic welding, or resistance welding processes.
• Familiarity with battery testing systems and end‑of‑line validation equipment.
• Experience implementing traceability systems and MES/ERP integration.
• Understanding of ISO9001, IATF16949, APQP, PPAP, and related quality standards.
• Six Sigma or Lean certification advantageous.
• Experience in start‑up or rapidly scaling manufacturing environments.

Role specific knowledge

• Lithium‑ion battery technologies and cell formats.
• Cylindrical and pouch cell assembly methodologies.
• High‑voltage battery pack architectures.
• Battery Management Systems (BMS) integration.
• HV electrical safety and insulation practices.
• Manufacturing process development and industrialisation.
• Prototype and low‑volume production environments.
• Welding and joining technologies for battery assemblies.
• Manufacturing quality systems and process controls.
• Root cause analysis and continuous improvement methodologies.
• Production tooling, fixtures, and test systems.
• Battery pack testing and validation processes.

Personal Attributes

• Highly technical with strong analytical and engineering problem‑solving capability.
• Hands‑on approach with willingness to work closely with production teams.
• Self‑motivated and adaptable within a start‑up environment.
• Strong leadership and mentoring capability.
• Detail‑oriented with strong commitment to quality and safety.
• Proactive and solutions‑focused mindset.
• Excellent communication and stakeholder engagement skills.
• Organised and capable of managing multiple priorities simultaneously.
• Resilient and comfortable operating in a fast‑paced, evolving business.
• Passion for battery technology, electrification, and advanced manufacturing.

Location and Travel

• You must be eligible to work in the UK and have no restrictions for world‑wide travel.
• This role is based at our Head Office in the UK, with flexibility for remote working up to 2 days a week.
• Working hours are 09h00 to 17h00, 5 days a week, however some travel is expected, and flexible working patterns are essential to the role.

We are committed to creating an inclusive workplace and welcome applications from all qualified candidates regardless of age, disability, gender identity, race, religion, sexual orientation, or background.