Senior HV Systems Design Engineer in Warwick

Our sister company, Futuremotiv is looking for a Senior HV Systems Engineer - Energy Storage & Power Distribution to join their expanding Team. We are looking for a hands-on team member who will embrace the company's “can-do” culture and professional business environment. The candidate must be adaptable, self-motivated, and technically capable.

The role will involve working directly with our customers and suppliers to develop and prototype-manufacture High Voltage (HV) battery systems. It spans mechanical design, CAD, thermal systems, electrical distribution system (EDS) integration and HV safety, and covers the full lifecycle from requirements management through design to final validation and testing.

Responsibilities:

• Benchmarking, feasibility studies and generation of design concepts
• Develop 3D design concepts and proposals, present for approval, and implement the approved proposal through to detailed design
• Design and development of HV components, e.g. batteries, power distribution units, and thermal management systems
• Design for Manufacture and Assembly (DFM/DFA) across component and system level designs
• Production of 2D manufacturing drawings from approved 3D designs
• Requirements decomposition and management
• Guide the simulation team on the analysis required and evaluate the simulation outputs
• Supplier and customer communication on technical issues and project management
• Component and system-level testing analysis results
• Application of HV isolation and safe working procedures across design, build and test activities
• Selection of materials and enclosure design accounting for dielectric clearance, creepage distances and environmental sealing (IP rating)

Technical Attributes:

• Excellent experience in powertrain / HV system engineering
• Strong CAD capability (CATIA / NX preferred), including 3D modelling and 2D manufacturing drawings
• Adept with design calculations including tolerance stack-ups, bolt sizing, and stress analysis
• Knowledge of different cell interconnect methods, busbars and welding types
• Experience of Lithium-Ion battery development and/or testing
• Familiarity with automotive industry processes, methods and standards
• Experience with the systems engineering V-cycle, including requirements creation, DFMEA and DVP generation
• Familiarity with regulations pertaining to HV systems within automotive and/or other industries (e.g. UN R100, FMVSS 305 or equivalent)
• Knowledge of battery design rules and standards (e.g. UN38.3, IEC 62660, ISO 6469) is a plus
• Familiarity with HV battery thermal management concepts
• Awareness of EMC/shielding considerations in HV mechanical design
• HV trained or willing to undertake HV training/certification (e.g. IMI Level 3/4 or equivalent)
• Effective root cause analysis and ensure permanent corrective actions are implemented for quality issues

Personal Attributes:

• Strong hands-on approach & can-do attitude
• Able to operate autonomously and as part of a team
• Ability to operate and communicate in an international, multi-cultural environment
• Excellent verbal and written communication skills appropriate for direct work with customers

Education required:

Bachelor's or master's degree in a relevant engineering discipline — Electrical, Mechanical, Automotive (or equivalent professional accreditation); candidates from an Electrical background with strong mechanical aptitude are encouraged to apply.