Lead Mechanical Design Engineer

About the role

Exponent Energy is looking for an experienced Mechanical Design Engineer with 8+ years of experience to own and deliver products for its flexible energy stack, which includes low-voltage batteries, chargers and connectors, high-voltage batteries, chargers and connectors, and vehicle integration kits. The engineer works with the product and engineering team behind the e^pack (battery pack) and e^pump (charging station).

Key responsibilities

• Review all designs under ownership before release, considering design for weight, volume, thermal performance and IP sealing, and ensuring serviceability and manufacturability (DFM/DFA)
• Contribute to project and program planning, including budgets, resources, timelines and tooling
• Review conceptual designs, theoretical calculations and tolerance stack analyses
• Develop and run test plans to validate subsystems and full product performance
• Conduct root cause analyses 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 stabilization (FMEA, DFX, DVP, inspection plans, etc.)

Required profile

• 8+ 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
• Quality of work, resilience after failure, strong ownership and willingness to get hands dirty

Required skills

• Mechanical design: structural design, thermal systems, fluid systems and electro-mechanical packaging
• Fluid systems, heat transfer (conductive/convective) and refrigeration/HVAC
• Materials knowledge: metals, plastics, composites and elastomers