Battery design and development - Electrical & Mechanical

For Electrical

Battery pack design, cell level testing, electrical debugging, BMS integration, validation of lithium ion battery systems for UAVs. 

Responsibilities

Battery Pack Design & Development

• Design and validate battery pack , including cell configuration, interconnections, busbars.
• Select cells to meet performance and safety requirements.
• Hands on experience with BMS integration with cells in battery pack
• Collaborate with mechanical and thermal teams to ensure integration with enclosures and cooling systems.

Cell & Pack Testing

• Perform cell level testing (capacity, impedance, cycle life, rate performance, abuse testing, etc.).
• Conduct battery pack testing under various charge/discharge profiles, thermal conditions, and load scenarios.
• Define test plans, prepare SOPs, and maintain test logs to ensure traceability.

Electrical Debugging & Root Cause Analysis

• Diagnose electrical and thermal issues at cell, module, and pack levels.
• Perform failure analysis using electrical measurements, teardown, and root-cause identification methodologies.
• Propose corrective actions, design improvements.

Required Skills & Competencies

• Strong knowledge of lithium-ion cell chemistry, degradation mechanisms, and testing methodologies.
• Hands on experience with thermal chambers, impedance analyzers and test automation setups.
• Proficiency in BMS fundamentals, fault detection, and data analysis.
• Familiarity with root cause analysis techniques.
• Assist in calibration, validation, and fault simulation of BMS features.

For Mechanical:

Strong background in mechanical design (Creo), product development, DfX principles and PLM (windchill) systems. 

Key Responsibilities:

• Lead the electro-mechanical design and development of products using Creo (3D CAD) tools.
• Drive concept-to-production mechanical design activities with a strong focus on DfX (Design for Manufacturing, Assembly, Testing, Cost, Reliability, etc.).
• Collaborate with electrical and embedded teams to ensure optimal electro-mechanical integration.
• Create and manage design documentation and BOMs within PLM systems (e.g., Windchill).
• Conduct design validation, testing, and support product reliability and quality initiatives.
• Provide inputs into early-stage product requirement definitions and contribute to DFMEA/PFMEA exercises.
• Understand and apply battery design fundamentals for mechanical integration in systems such as battery packs or modules.
• Support prototype builds, pilot runs, and ramp-up activities in collaboration with production teams.

•       Understanding of manufacturing processes like injection molding, sheet metal, machining, composite and basic tool principles.

•       Familiarity with thermal management design and simulation.