Mechanical Design Engineer – E+ES (Battery and Power Systems)

Career Area:

Job Description:

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Mechanical Design Engineer – E+ES (Battery and Power Systems)
 

Role Overview
Mechanical Design Engineer responsible for concept-to-release mechanical design and product realization of battery systems and power electronics for energy and power applications. The role focuses on robust packaging, structural integrity, manufacturable designs, and compliance with electrical safety and environmental requirements, working closely with cross-functional teams through structured design reviews and NPI gateways.

Key Responsibilities:

• Concept Development & Engineering Solutions:
• Develop and compare concepts (architecture, packaging, mounting strategy, service access) and translate requirements into feasible engineering solutions.
• Generate layout options and trade studies (mass, cost, manufacturability, serviceability, thermal paths, sealing/IP, safety).
• Drive design decisions with clear rationale, assumptions, and risk/mitigation plans.

Mechanical Design & Packaging:

• Create 3D CAD models for sheet metal, castings, extrusions, brackets, enclosures, and interfaces supporting batteries and power electronics
• Develop 3D packaging layouts considering space claim, clearances, creep/clearance for HV, assembly sequence, and serviceability
• Integrate cooling hardware (coolant pipes/plates), HV–LV harness routing provisions, protection features, and auxiliary components within the mechanical package.

Select materials and isolations considering strength, thermal performance, electrical insulation interfaces, corrosion (including galvanic), and environmental exposure.

Design Definition, Controls & Release:

• Apply GD&T (ASME Y14.5) and perform tolerance stack-ups for critical interfaces and sealing features.
• Develop and maintain BOMs, part numbers, and design releases using Teamcenter PLM.
• Define interface control documents (ICDs) and support configuration management across development phases.
• Design Verification and support:
• Define load cases and boundary conditions for defined operating, handling, transport, and mounting scenarios.
• Perform medium to high fidelity simulations to support design decisions.
• Support test planning, instrumentation correlation (strain/vibration/thermal), and issue resolution based on test findings.
• Support resolving field issues by proposing and validating ICA and PCA
• Manufacturing & Build Support:
• Implement DFM/DFA and process selection (sheet metal forming, welding, casting, molding) to ensure manufacturability and assembly robustness.
• Address variation, distortion, residual stress, and dimensional control with suppliers and internal manufacturing teams.
• Support DV/PV builds, prototype iterations, and lessons-learned incorporation into subsequent releases.

Design Reviews, Quality & Risk Management:
Plan and execute structured design reviews (Concept/Architecture, Preliminary Design Review, Critical Design Review, drawing/design release reviews) with clear action tracking.

• Execute DFMEA/PFMEA and drive risk mitigation, validation evidence, and closure of open items.
• Drive APQP deliverables and support PPAP documentation as required.
• Supplier Technical Engagement:
• Evaluate supplier capability for fabrication, welding, dimensional control, and quality; validate tooling and process capability.
• Lead technical discussions, drawing clarifications, and issue resolution to meet cost, quality, and schedule targets.
   

Required Qualifications:

• Bachelor’s/Master’s in Mechanical/Aerospace Engineering or similar.
• 3+ years of experience in mechanical design for battery systems, power electronics, or energy & power applications.
• Proficiency with 3D CAD and drawing practices; experience with Teamcenter PLM for product data management and release processes.
• Working knowledge of HV packaging constraints (clearance/creepage), sealing/IP, and integration of thermal and harness routing provisions.

Additional Information: This job required 5days working from office.

Posting Dates:

Caterpillar is an Equal Opportunity Employer.  Qualified applicants of any age are encouraged to apply

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