Battery Design Engineer
Location: [Bangalore, India]
Department: Engineering and 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 (ft.energy), 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.
