Mechanical Design Engineer - Sheet Metal & Packaging

About the role

Exponent Energy, co-founded by former Ather Energy leaders, builds the e^pack (battery pack) and e^pump (charging station) to enable 15-minute rapid charging for EVs. It is looking for an experienced Mechanical Design Engineer with 4 to 6 years of experience to develop sheet metal components such as enclosures and electrical panels, and to optimise packaging for the e^pump. The engineer drives structural and thermal designs that are efficient, cost-effective and manufacturable.

Key responsibilities

• Design for weight, volume, thermal performance and IP sealing, ensuring serviceability and manufacturability (DFM/DFA)
• Perform conceptual designs, theoretical calculations and tolerance stack analyses
• Develop and run test plans to validate subsystems and full product performance
• Carry out root cause analyses for issues found during testing and field deployment
• Work with manufacturers, assembly teams and mold designers to refine designs
• Document the product development cycle from concept to production stabilisation (FMEA, DFX, DVP, inspection plans, etc.)

Required profile

• 4 to 6 years of experience
• Proven track record of taking a product from concept to production
• Strong mathematical and analytical skills
• Quality of work, resilience and a problem-solving approach

Required skills

• Structural design, thermal systems and electro-mechanical packaging
• Fluid systems, heat transfer (conductive/convective) and refrigeration basics
• Mechanical assembly, IP sealing and packaging optimisation
• Materials knowledge: metals, plastics, composites and elastomers