Manufacturing Engineer - Electrical Hardware

About the role

Exponent Energy is hiring a Manufacturing Engineer for its Manufacturing Engineering and Supplier Development team in Bengaluru. The team develops and industrialises electrical hardware systems for EV battery packs, BMS systems and rapid charging products, focusing on scalable, reliable manufacturing processes for wiring harnesses, PCBAs and electrical assemblies. The role combines electrical hardware knowledge, manufacturing process expertise and supplier development.

Key responsibilities

• Own the development and industrialisation of wiring harnesses and PCBAs made at supplier facilities, working with design, manufacturing and quality teams.
• Lead development of signal and power wiring harnesses for EV battery and charging systems, covering low-current signal to high-current power harnesses (0.5 sq.mm to 500 sq.mm).
• Support processes such as wire cutting and stripping, crimping and terminal selection, ultrasonic welding, connector assembly, harness routing, overmoulding and insulation, and evaluate manufacturability, reliability and serviceability.
• Ensure compliance with electrical safety, insulation and current-carrying requirements and work with vendors to improve process capability, quality and delivery.
• Develop understanding of PCBA manufacturing for BMS and chargers, including SMT, reflow and wave soldering, AOI/SPI inspection, functional testing and ICT, and identify soldering, thermal and component-handling risks.
• Support manufacturability reviews, supplier discussions and NPI builds, pilot production and validation, and drive closure of quality and process issues.
• Conduct process audits, capability assessments and traceability checks at supplier facilities, and drive process capability improvement, defect reduction and root cause analysis.

Required profile

• Bachelor's degree in Electrical, Electronics, Mechatronics or a related engineering field.
• Minimum 5 years of experience in electrical hardware manufacturing or supplier process development.
• Experience with suppliers and external manufacturing partners.
• Preferred: EV battery pack, BMS or charger manufacturing experience, and familiarity with IPC standards, crimp quality standards and electrical validation.

Required skills

• Wiring harness manufacturing processes and connectors, terminals and crimping standards.
• PCBA manufacturing processes and manufacturing risks.
• Preferred: ICT, FCT and end-of-line testing, DFMEA, PFMEA, APQP, MES and traceability systems.