Mechanical Engineer- Battery Pack Design

Role: Mechanical Engineer – Battery Pack Design

Location: IIT Madras Research Park, Chennai, TN

About Zenfinity Energy

Zenfinity Energy, incubated at IIT Madras, is building India's most advanced lithium-ion battery systems. We design and manufacture high-reliability battery packs for electric two-wheelers, three-wheelers, commercial vehicles, and stationary energy storage—engineered specifically for India's extreme heat, dust, and demanding operating conditions.

What makes us different:

• End-to-end battery engineering: from cell chemistry to BMS, thermal management, firmware, and pack integration
• AI-powered digital twin that validates every pack in real time
• India's first blockchain-based Battery Passport for complete lifecycle traceability
• Mission: Build India's most trusted battery innovation company and enable a transparent, circular battery economy

The Role

We're looking for a Mechanical Engineer with proven hands-on experience in lithium-ion battery pack design. This is not an entry-level or generalist position. You will own the mechanical and thermal architecture of our battery packs from concept through mass production.

What You'll Do?

• Lead mechanical and thermal design of battery packs for EVs and energy storage systems.
• Design pack architecture: module arrangement, structural framework, enclosure geometry, and safety integration
• Develop and optimize thermal management systems (active cooling, cold plates, passive heat dissipation, phase change materials) for India's 45°C+ ambient conditions
• Create detailed 3D CAD models, engineering drawings, and manufacturing documentation using SolidWorks, CATIA
• Conduct FEA simulations for stress, vibration, and thermal analysis to ensure pack durability
• Lead DFMEA (Design Failure Mode & Effects Analysis) and risk mitigation for pack-level design
• Ensure compliance with AIS-156, ISO 16750, and other battery safety standards
• Collaborate with BMS, electrical, firmware, and manufacturing teams to integrate systems seamlessly
• Support prototype builds, validation testing, supplier engagement, and production ramp-up

Requirements

• 2–5+ years of hands-on experience designing lithium-ion battery packs in automotive, EV, or energy storage applications
• Strong mechanical and thermal engineering fundamentals: heat transfer, stress analysis, materials selection
• Expert-level proficiency in CAD tools: SolidWorks, CATIA, or Creo
• Experience with FEA simulation tools: ANSYS, ABAQUS, or COMSOL
• Deep understanding of battery pack architecture: cell types (cylindrical, prismatic, pouch), module assembly, thermal management strategies, BMS integration
• Knowledge of manufacturing processes: welding (spot, laser, ultrasonic), molding, sheet metal, assembly automation
• Familiarity with battery safety standards: AIS-156 (India), ISO 16750, or equivalent
• Proven track record taking designs from concept to production
• Bachelor's degree in Mechanical Engineering (M.Tech preferred)

Highly Preferred

• Experience with AIS-156 compliance for L-category vehicles (2W/3W EVs)
• Experience with ESS and BESS
• Knowledge of DFMEA, PFMEA, and DfX methodologies (Design for Manufacturing, Assembly, Testing)
• Experience with advanced thermal management (liquid cooling, composite materials, thermal optimization)

Location & Work Model

• Location: Chennai, India (IIT Madras Research Park )
• Work Model: On-site

How to Apply

Send your application to:

with subject:
"Mechanical Engineer – Battery Pack Design
Please include: Resume/CV with specific battery pack design projects and outcomes.

Equal Opportunity

Zenfinity Energy is committed to diversity, equity, and inclusion. We welcome applications from engineers of all backgrounds, genders, and communities. If you have the skills and passion for battery innovation, we want to hear from you.