EV Battery Pack Design Engineer in Banbury

Job Title: EV Battery Pack Design Engineer

Location: Banbury, UK

Duration: 12 months fixed term employment

No of positions: 1

Hybrid work model: 5 days/week from client location

Experience: 5-12 Years Domain: Electric Vehicles, Battery Pack Engineering, Energy Storage Systems

About The Role

We are looking for a skilled EV Battery Pack Design Engineer to support the design, development, and validation of high-voltage battery packs for electric vehicles. The role focuses on mechanical design, packaging, thermal integration, component development, CAD modelling, and engineering release activities while working closely with cross-functional teams to meet performance, safety, quality, and cost targets.

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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