Mechanical Design Engineer - Battery Systems

This role is Outside IR35

UK based Remote working

Job Title: Senior Mechanical Design Engineer - Electronics Enclosure & Battery Systems

Role Overview:

The Senior Mechanical Design Engineer will be responsible for the mechanical design of ruggedized enclosures, battery modules, and supporting systems. The ideal candidate has deep expertise in mechanical CAD, materials, and manufacturing techniques for high-reliability applications. This position is ideal for a proactive, detail-oriented engineer who thrives in a collaborative and fast-moving project structure.

Key Responsibilities:

• Develop and manage mechanical designs using Autodesk Fusion 360 or equivalent CAD tools (license required or provided by candidate).
• Design battery packs and busbars for power systems, ensuring safety, reliability, and thermal performance.
• Create enclosure designs that meet IP67-IP68 ingress protection requirements.
• Apply DFM/DFA principles for plastic moulding, sheet metal, and laser welding fabrication.
• Perform tolerance stack-up analysis and apply electrical clearance and creepage rules.
• Model cable harnesses and integrate effective strain relief and routing strategies.
• Select and implement robust fixing methods: adhesives, rivets, welds, mechanical fasteners.
• Ensure compliance with environmental and mechanical standards including:

o Corrosion: AECTP-300 Method 309 o Dust & Sand: AECTP-300 Method 313 o Shock & Vibration: DEF STAN 00-35 (M1-M6) o Rain, Solar, Immersion: AECTP-300 Methods 305, 307, 310

• Collaborate closely with electrical, software, and manufacturing teams to ensure integrated, production-ready designs.
• Occasionally participate in on-site system integration activities in the UK (location to be confirmed).

Requirements:

• Minimum 8 years of mechanical design experience in battery, electronics, or automotive industries.
• Proficient with Autodesk Fusion 360 or similar MCAD tools (must provide own license if not using Fusion 360).
• Proven experience in:
• o Battery module and busbar mechanical design o Enclosure design with IP67-IP68 protection o Harness and cable modelling o Plastic injection moulding and sheet metal design o Laser welding and other joining techniques o Tolerance analysis, electrical safety spacing o Designing for mass manufacturing and assembly

• Deep understanding of environmental and mechanical compliance standards.

Preferred Skills:

• FEA or simulation experience in thermal, static, or dynamic mechanical loading scenarios.
• Experience in rugged environments (defence, automotive, industrial sectors).
• Experience working in a milestone-driven development environment.

Personality:

• Initiative-taker with a creative and solutions-focused mindset.
• Strong communication and problem-solving skills.
• Comfortable working independently and delivering results