Battery Pack Design

About TechlanzTechlanz is a Bengaluru based company founded by IIT alumni with a core focus on next generation drone battery technologies. The company provides end-to-end engineering services, product development support and advanced training & certification programs in Battery and AI space. Techlanz is also developing Battery Digital Twin in combination with the battery tech.Position OverviewThe Battery Pack Design and Development Engineer will be a key member of our engineering team, responsible for the end-to-end design, development, and validation of battery packs utilizing pouch cells. This role requires a deep understanding of mechanical and thermal design principles, as well as a strong grasp of the unique challenges and advantages of working with pouch cell technology. The ideal candidate will be a hands-on engineer with a passion for innovation and a proven track record of bringing battery pack designs from concept to production.Job ResponsibilitiesConceptual and Detailed Design:Lead the mechanical design of battery packs, including the structural framework, module arrangement, and integration of pouch cells. Develop detailed 3D CAD models and 2D drawings of battery pack components and assemblies.- Pouch & Cylindrical Cell Integration:Design and optimize cell holders, compression mechanisms, and electrical interconnects specifically for pouch cells, considering factors such as swelling, thermal expansion, and vibration.- Thermal Management:Develop and implement effective thermal management solutions for pouch & cylindrical cell battery packs, including air and liquid cooling systems. Perform thermal simulations (CFD) to validate and optimize cooling performance.- Structural Analysis:Conduct Finite Element Analysis (FEA) to ensure the structural integrity and durability of the battery pack under various load conditions, including shock and vibration.- Prototyping and Testing:Build and test prototype battery packs to validate design concepts. Develop and execute comprehensive test plans, including performance, safety, and reliability testing.- Design for Manufacturability (DFM) and Assembly (DFA):Collaborate with manufacturing engineers to ensure that the battery pack design is optimized for high-volume production, cost-effectiveness, and ease of assembly.- Component Selection and Supplier Interaction:Select and qualify mechanical and electrical components for the battery pack. Work closely with vendors to ensure components meet design specifications and quality standards.- Cross-Functional Collaboration:Work in a multidisciplinary team with electrical engineers, software engineers, and project managers to ensure seamless integration of the battery pack into the overall system.- Documentation:Create and maintain detailed design documentation, including bill of materials (BOM), design specifications, and test reports- Apply DFMEA/PFMEA, DFM/DFA, tolerance stack-ups, and GD&T; drive design reviews and track risk burndown to SOP.- Specify thermal management (air/liquid, TIMs, cold plates, venting) and validate thermal runaway mitigation and propagation resistance.- Define electrical architecture with BMS (sensing, HV/LV harnessing, contactors, fusing, EMI/EMC) and align with functional safety (ISO targets.- Guide material and process selection (aluminium enclosures, busbars, gaskets, adhesives, potting; laser/ultrasonic welding) for performance and IP67/69K sealing.- Lead supplier development for cells, interconnects, enclosures, and harnesses; execute APQP/PPAP and incoming quality controls.- Use CAD/CAE to iterate designs (Creo/CATIA; structural/thermal simulation) and maintain up-to-date BoMs, drawings, and ECR/ECOs.- Benchmark packs (LFP/NMC) and run cost/weight/packaging trade-offs; present decision-ready options to leadership and customers.QualificationsB.E./B.Tech (Mechanical/Automotive/Electrical/Mechatronics);4–8 years' experience in battery pack design and NPD with strong exposure to pouch-cell based modules/packs for EVs.Proven ownership of DVP&R and validation for battery packs; familiarity with ARAI/ICAT test programs.Working knowledge of AIS 156 requirements and change impacts on design, controls, and validation.Understanding of BIS IS 17855 performance testing and IEC 62660 series cell tests; ability to translate test data into design actions.Experience ensuring UN 38.3 transport compliance and generating/maintaining Test Summaries with suppliers.Familiarity with UL 2580 pack-level safety expectations for global programs is a plus.Strong DFMEA/PFMEA, DFM/DFA, GD&T, tolerance stacks; hands-on with prototype builds and failure analysis (tear-downs, 5-Why, 8D).Proficiency in Creo or CATIA; exposure to thermal/structural CAE (ANSYS/Fluent/COMSOL/HyperMesh) and data analysis (MATLAB/Excel/Python).Cross-functional leadership with BMS/controls, manufacturing, sourcing, and suppliers; clear technical documentation and stakeholder communicationSkillsExcellent 3D modelling, thermal and structural CAE analysis , Thermal Management, design files release management, DFMEA, DVP&R, AIS 156, ISO 26262, UN 38.3, Creo/CATIAWhy Join Us?Be part of a fast-growing, IIT alumni-founded company driving innovation in next-gen battery and AI technologies.Work on cutting-edge projects in EVs, drones, and digital twin solutions with real-world impact.Gain cross-functional exposure across engineering, product development, and R&D.Access to advanced training, certifications, and mentorship to accelerate your career growth.Collaborative, innovative, and learning-focused culture where your ideas matter.If you are ready to take on this challenge and start a rewarding career with Techlanz, we encourage you to apply now at the mentioned link below;