Senior Mechanical Engineer, High-Voltage Design

The role

You will drive the high voltage requirements, design, simulation, and testing of power systems. You will design electro-mechanical sub-assemblies that deliver power and control signals within battery enclosures.

What you will do

• Provide technical leadership and mentorship within a multidisciplinary engineering team
• Own the High Voltage design of battery products including busbars, cables, isolation, grounding, and enclosures
• Design and optimize high voltage joints for reliability and performance
• Address challenges related to electronics packaging including electrical isolation, sealing, thermal regulation, and shock mitigation
• Lead RCAs and cross-functional interface design
• Perform mechanical design analysis including thermal, structural, design for assembly, and design for test
• Own the design from conception through all iterations to mass-production
• Create drawing packages and manufacturing instructions for parts and assemblies
• Design and develop electromechanical and electrical systems for test stand safety and improvements

Required qualifications

• Degree in Mechanical/Mechatronics Engineering or a related field
• Bachelor's with 6+ years of relevant experience developing medium to high volume products, or master's with 4+ years
• Proven experience with electromechanical design of power distribution systems, electrical circuits, and protection devices
• Ability to model resistive losses, size and optimize busbar geometries, and design for high voltage creepage and clearance
• Expertise in engineering analysis including thermal, CFD, structural, 1D modelling, cost modelling, and optimizations
• Strong mechanical and electrical engineering fundamentals, GD&T, and first principles hand calculations
• Experienced user of CAD (SolidWorks, NX, etc.)
• Direct experience with medium-to-high-volume manufacturing, fabrication, and prototyping techniques
• Tolerance stack-up analysis
• Tight-tolerance component design
• DFM/DFA principles
• Ability to model resistive losses and run current density analysis

Nice to have

• Familiar with electrical standards (NEC)
• Experience with battery and power conversion standards (UL9540, UL1741)
• Strong leadership, mentoring, communication, collaboration, and stakeholder engagement skills

Benefits

• Competitive salaries
• Stock options
• 100% medical, dental, and vision premiums for full-time employees
• 80% healthcare premiums for dependents
• At least 12 weeks of paid leave for new parents
• Up to 20 weeks of paid leave for birthing parents
• Generous vacation policies

About the company

Form Energy is an American manufacturing and energy technology company. They are developing cost-effective, multi-day energy storage technology to keep the electric grid secure and reliable.