Senior/Staff Battery Mechanical Design Engineer

At Heart Aerospace we develop the ES-30, a regional hybrid-electric airplane with a capacity of 30 passengers, an electric zero-emission range of 200 km and an extended hybrid range of 400 km. Heart is targeting type certification of the ES-30 by the end of the decade.

Your mission

Heart Aerospace is seeking a highly motivated and experienced Battery Design Engineer to join our growing and dynamic team. In this role, you will be a key contributor to the design, development, testing, and optimization of advanced battery systems specifically designed for the demanding requirements of electric aerospace applications. You will leverage your deep understanding of design methodologies and approaches to drive innovation and ensure the highest levels of performance, safety and reliability. You will translate system-level requirements into robust, certifiable mechanical designs, playing a critical role in electrifying the future of flight. 

Key responsibilities include but are not limited to:

• Lead the mechanical design, and development of various battery mechanical systems, including battery cells, module design, module housings, high voltage distribution and full pack assemblies using advanced CAD tools (e.g. NX).
• Develop innovative and weight-optimized structural solutions to meet aircraft-level vibration, shock, and crash safety requirements.
• Create and manage detailed engineering drawings and specifications, applying a high standard of Geometric Dimensioning and Tolerancing (GD&T).
• Generate high quality DFMEA’s and DVP&R’s
• Define and execute comprehensive validation and verification test plans (mechanical, environmental, and abuse testing) to qualify designs for aerospace applications.
• Collaborate cross-functionally with Electrical, Thermal, and System Integration teams to ensure seamless integration of the battery system into the aircraft structure.
• Ensure all designs meet relevant aerospace safety and certification standards (e.g., FAA, EASA, DO-160, DO-311, etc.).
• Support the transition of designs from prototype to high-volume manufacturing, focusing on Design for Manufacturing (DFM) and Design for Assembly (DFA).
• Drive program schedule, timelines. Ensure releases are on time to meet vehicle program milestones.
• Mentor junior engineers and serve as a technical resource within the mechanical engineering team.

You will initially report to the Director of Battery and belong to the Battery team. Your place of work will be at our office located in El Segundo, CA (Los Angeles).

Skills & Requirements:
You'll Bring These Qualifications for Senior Battery Mechanical Design Engineer

• Minimum of 5+ years of experience in mechanical engineering design, with a significant focus on high-voltage battery systems (cell, module, or pack level).
• Proficiency in a mechanical CAD tool (e.g., Siemens NX, CATIA).
• Proficiency with FEA software and hand calculations in structural and thermal analysis using industry-standard FEA/CFD software (e.g., ANSYS, Abaqus, Star-CCM+).
• Deep understanding of structural mechanics, fatigue analysis, and thermal management principles as applied to electrochemical systems.
• Excellent written and verbal communication skills, including the ability to present complex technical information clearly.
• Strong problem-solving skills and the ability to perform root cause analysis.
• Ability to work independently and collaboratively in a fast-paced, dynamic environment.

You'll Bring These Qualifications for Staff Battery Mechanical Design Engineer

• Minimum of 8+ years of experience in mechanical engineering design, with a significant focus on high-voltage battery systems (cell, module, or pack level).
• Expert proficiency in a mechanical CAD tool (e.g., Siemens NX, CATIA).
• Expert proficiency with FEA software and hand calculations in structural and thermal analysis using industry-standard FEA/CFD software (e.g., ANSYS, Abaqus, Star-CCM+).
• A strong foundation in material science and selection, particularly with respect to lightweight materials like aluminum alloys, high-performance plastics, and composites.
• In-depth knowledge of Lithium-ion cell mechanical behavior and failure mechanisms under stress.
• Proven experience in defining test methods and interpreting data from battery physical validation (vibration, shock, crush, fire propagation).
• Excellent written and verbal communication skills, including the ability to present complex technical information clearly.
• Strong problem-solving skills and the ability to perform root cause analysis.
• Ability to work independently and collaboratively in a fast-paced, dynamic environment.

These Qualifications Would Be Nice to Have:

• Prior experience designing components for certified aerospace or high-reliability automotive/EV applications.
• Familiarity with aerospace certification processes and design standards (e.g., DO-160, DO-311A, MIL-STD, UN 38.3, IEC standards).
• Hands-on experience with design for sealing and ingress protection (IP ratings).
• Experience with BMS enclosure and interconnect design.
• Knowledge of manufacturing processes unique to battery pack construction (e.g., laser welding, potting, sealing).

Education: 

Required: Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a closely related technical field.

Preferred: Master's or Ph.D. degree in Mechanical Engineering or a specialization relevant to energy storage.