Design Engineer ( EV Battery) in Banbury

Key Responsibilities

• Battery Pack Design & Packaging

  Design and develop battery pack components including enclosures, structural parts, cooling systems, busbars, brackets, and mounting systems.

  Create 3D CAD models, assemblies, 2D drawings, and BOMs.

  Support battery pack packaging studies considering vehicle integration, serviceability, manufacturability, and safety requirements.

  Define and manage component interfaces and packaging constraints.

• Mechanical Design & Product Development

  Develop detailed designs from concept through production release.

  Apply GD&T principles and engineering standards in component design.

  Support DFMEA, DVP&R, design reviews, and engineering change management activities.

  Collaborate with suppliers and internal teams for component development and issue resolution.

  Ensure compliance with DFM/DFA guidelines and automotive quality standards.

• CAE & Validation Support

  Work with CAE teams to support structural, thermal, vibration, and crash simulations.

  Review simulation results and implement design improvements.

  Support DV/PV testing, environmental testing, vibration testing, and performance validation.

  Participate in root cause analysis and corrective action implementation.

• Cross-Functional Collaboration

  Coordinate with battery, thermal, electrical, BMS, manufacturing, and vehicle integration teams.

  Support technical discussions with suppliers and program stakeholders.

  Track engineering deliverables, open issues, and design changes throughout the development cycle.

  Ensure timely release of engineering documentation and design updates.

• Manufacturing & Launch Support

  Support prototype build activities and production trials.

  Collaborate with manufacturing teams on tooling, assembly processes, and design optimization.

  Participate in PFMEA reviews and process validation activities.

  Support launch readiness and production issue resolution.

Required Skills & Qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Automotive Engineering, or related discipline.

• 5+ years of experience in automotive design engineering, preferably in EV battery pack development.

• Proficiency in CAD tools such as CATIA V5 & CATIA V6.

• Strong understanding of sheet metal, castings, extrusions, plastics, and structural design.

• Experience with GD&T, DFMEA, DVP&R, BOM management, and engineering release processes.

• Knowledge of battery pack structures, thermal management systems, and HV component integration.

• Ability to interpret CAE and test results for design optimization.

• Strong problem-solving, communication, and teamwork skills.

Preferred Qualifications

• Experience working with EV OEMs or Tier-1 suppliers.

• Knowledge of lithium-ion battery systems and HV safety requirements.

Familiarity with battery pack manufacturing processes such as welding, bonding, sealing, and assembly.

• Exposure to PLM tools.

• Experience supporting prototype builds and production launches.

• Understanding of automotive standards and regulations related to EV battery systems.

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