Sr Engineer, Mechanical Design – High Voltage EV Systems

About the role

We are seeking an experienced Mechanical Design Engineer with expertise in packaging high-voltage systems (400 V – 800 V) for electric vehicles. This role focuses on designing compact, reliable, and safe enclosures and packaging for circuit board assemblies, busbars, harnesses, and high-voltage components. You’ll work closely with electrical and systems engineers to ensure that mechanical packaging solutions meet demanding electrical, thermal, and safety requirements.

What you'll do

• Package high-voltage (400–800 V) automotive systems, including circuit board assemblies, busbars, harnesses, and power distribution units.

• Develop dense, compact layouts that optimize thermal performance, dielectric strength, clearances/creepage, and long-term reliability.

• Apply a working knowledge of dielectric properties of materials, thermal management, and material creep to ensure safe, durable designs.

• Collaborate with electrical engineers on component placement, routing, and packaging trade-offs.

• Incorporate EMI/EMC mitigation strategies into packaging solutions.

• Produce detailed 3D CAD models and 2D drawings (CATIA preferred; willingness to learn required).

• Support harness routing and packaging using Arcadia (or learn quickly on the job).

• Participate in design reviews and work closely with suppliers to ensure manufacturable solutions.

• Hands on assembly of the designs for proving out design and creating work instructions.

Qualifications

• Proven track record in packaging 400–800 V EV components (circuit board assemblies, busbars, harnesses, distribution units).

• Read and understand system schematics and wiring diagrams.

• Proficiency in 3D CAD tools (CATIA preferred) with ability to deliver production-ready models and drawings.

• Familiarity with EMI/EMC design considerations in packaging.

• Bonus: Experience with Arcadia harness design tool.

Team Structure

• Individual contributor; collaborate with other teams and individuals, as necessary

Required Experience

• 5+ years of experience in mechanical packaging of high-voltage systems for automotive or related industries

Educational Requirements

• Bachelor’s degree (or higher) in Mechanical Engineering or related field

Salary + Benefits

• Market competitive compensation package
• Stock option grants
• Fully funded benefits package for employee + dependents
• Generous Flexible Time Away policy