Battery Design Engineer

Location:
[Bangalore, India]

Department:
Engineering & Product Development

Experience Required:
Minimum 5 Years

Employment Type:
Full-time

About the Role

We are looking for a Battery Design Engineer with deep expertise in designing and developing high performance lithium-ion and lithium iron phosphate (LFP) battery packs for electric two-wheelers and three-wheelers. The ideal candidate should have a strong foundation in SolidWorks, structural and thermal design, battery pack electricals, and experience taking products from concept to mass production. You will be responsible for end-to-end design — from mechanical layout and cell configuration to enclosure design, busbar fabrication, and manufacturing validation —ensuring the battery packs meet performance, safety, and manufacturability standards, particularly for fast-charging applications.

Key Responsibilities

• Lead mechanical and structural design of lithium-ion and LFP battery packs using SolidWorks (mandatory).

• Develop designs for both cylindrical and prismatic cell formats.

• Design busbars (copper, aluminum, nickel, hybrid) with emphasis on current carrying capacity, heat dissipation, and manufacturability.

• Conduct structural, vibration, and thermal analysis to ensure reliability under road and environmental conditions.

• Design battery enclosures with consideration for IP rating, cooling, safety, and manufacturability.

• Work closely with electrical engineers to integrate BMS, sensors, fuses, and wiring harnesses seamlessly within the pack.

• Define and validate fast-charging mechanical and thermal design requirements.

• Collaborate with manufacturing and supply chain teams to transition designs from pilot to production scale.

• Support prototype assembly, design validation, and root cause analysis for field issues.

• Maintain accurate design documentation, BOMs, drawings, and revision histories.

• Ensure designs adhere to relevant EV and battery safety standards (AIS-156, IP67, UN38.3, etc.).

• Apply DFM/DFA (Design for Manufacturing/Assembly) and project management principles to ensure timely delivery of design milestones.

Key Skills & Requirements

• Education: B.E./B.Tech in Mechanical Engineering, Mechatronics, or equivalent.

• Experience: Minimum 5 years in battery pack design within the EV industry.

• Proficiency in SolidWorks — advanced 3D modeling, assemblies, motion study, and drawings.

• Hands-on experience designing packs with cylindrical (e.g., 18650/21700) and prismatic cells.

• Understanding of battery electricals — series/parallel configurations, insulation, creepage/clearance distances.

• Strong grasp of thermal management and heat dissipation principles in fastcharging environments.

• Experience in metal fabrication, CNC machining, sheet metal, and plastic molding processes.

• Exposure to structural FEA, vibration, and drop testing simulations.

• Familiarity with battery integration in EVs, especially 2W and 3W platforms.

• Proven track record of taking at least one battery product from prototype to mass production.

• Strong documentation and communication skills, with the ability to work crossfunctionally.

• Knowledge of PDM/PLM systems is an added advantage.

• Understanding of GD&T, tolerance stack-up analysis, and design validation testing.

Desirable Attributes

• Experience working with fast-charging battery packs (≤15 minutes charge time).

• Familiar with thermal simulation tools (Ansys, SolidWorks Simulation, etc.).

• Exposure to IP-rated design and safety-critical systems.

• A structured, analytical, and detail-oriented design mindset.

• Hands-on experience working in factory and prototyping environments.

• Strong sense of ownership, accountability, and design discipline.

Why Join Us

At Flextron ), we are revolutionizing the way electric vehicles charge —building ultra-fast charging batteries and intelligent energy systems that enable sustainable mobility. You'll be part of a team that's redefining battery performance, speed, and reliability for India's EV ecosystem.