Senior Mechanical Design Engineer

About the role

Exponent Energy, which builds the e^pump (charging station) and e^pack (battery pack) for 15-minute rapid charging, is looking for a Senior Mechanical Design Engineer in Bengaluru. Working with the engineering team, you will develop sheet metal components such as enclosures and electrical panels and optimise packaging for the e^pump, driving structural and thermal designs that are efficient, cost-effective and manufacturable.

Key responsibilities

• Design for weight, volume, thermal performance and IP sealing while 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.
• Conduct root cause analyses (RCAs) for issues during testing and field deployment.
• Work with manufacturers, assembly teams and mold designers to refine designs based on feedback.
• Document the product development cycle from concept to production stabilisation (FMEA, DFX, DVP, inspection plans, etc.).

Required profile

• 5+ years of experience.
• Proven track record of taking a product from concept to production.
• Strong mathematical and analytical skills.
• Hands-on experience with mechanical assembly, IP sealing and packaging optimisation.

Required skills

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