Sr. Mechanical Design Engineer, Battery Pack

Supernal is at the forefront of creating emerging mobility solutions that will foster the development of human-centered cities. We are designing a completely new electric vertical take-off and landing (eVTOL) aircraft tailored to the mobility needs of future cities. This allows passengers a seamless intermodal journey that safely transports them to their final destination. We fuse research in autonomy, robotics, aviation and services to define a new category of mobility for the world’s communities. We believe in creative thinking and collaboration to help build a better mobility experience for everyone, improving people’s ability to move – whether for work or play.

What we do:

The Mechanical Design Engineer will be responsible for the mechanical design of the battery module and pack components and subsystems. EVTOL battery systems contain high voltage bussing and insulation, an array of cells with structural, thermal, and electrical interfaces, thermal systems, current collection and welded interconnects, printed circuit boards, wiring harnesses, breathers, and vents, and mitigations for abuse scenarios such as thermal runaway, short circuit, and fluid susceptibility. This role will be responsible for the mechanical design, component, and subsystem level validation, as well as the introduction into volume manufacturing and service of these components for the Supernal battery pack designs.

The Battery Pack Team is responsible for designing and prototyping high-voltage and high-power battery systems in electrified aircraft. The Mechanical Design Engineer for Battery Pack is critical to the Energy Storage System (ESS) development process, which includes conceptual designs, component selection, prototype builds, and launch designs for volume manufacture. This role works closely with battery systems engineers, test engineers, and product integration engineers to ensure a robust ESS is designed, built, and incorporated into the eVTOL aircraft.

Supernal provides an inviting open-space workplace designed to foster collaboration, which aligns with one of our core values. This position is required to work on-site 5 days a week.

What you can do:

• Drive mechanical design of electrical components, interconnects, and electromechanical subsystem designs from conceptual and requirements development through production
• Select, prove, and implement the application of existing technologies to internal product development and develop new technologies to improve product metrics
• Provide technical expertise and mentorship to team in mechanical design of electronic components: bus bars, interconnects, bolted joints, seals, structural components, enclosures, brackets, closures, insulative parts
• Define the specifications of electronic components, including dimensional, dielectric, functional, performance, reliability, survivability, component, and interface manufacturing
• Perform fundamental prototyping, testing, and analysis tasks and provide assistance for advanced analysis and validation testing
• Identify the root cause of issues in prototype, validation, and production stages and help in finding solutions for them
• Communicate work progress to department leadership through written and live updates, representing both individual and team efforts
• Collaborate with teams at Supernal sites and meet with suppliers for technology development, process validation, and issue resolution
• Build relationships with critical multi-functional teams in electrical design, testing, safety, abuse, manufacturing, systems, certification, and airframes
• Partner with PMO organization to implement build plan
• Up to 10% of domestic and international travel
• Other duties as assigned

What you can contribute:

• Bachelor’s degree in mechanical engineering, electrical engineering, or relevant field required
• Minimum of five (5) years of experience in electromechanical component and subsystem design (an equivalent combination of education and experience may be considered)
• Experience in designing electronic components: wire harnesses, connectors, flex printed circuit boards, laminated bus bars, voltage, current, and temperature sensing circuits
• Experience designing for volume assembly, including manual and automated processes
• Ability to package electronics to achieve mass, thermal performance, sealing requirements, electrical grounding behavior, mechanical durability
• Knowledge of mechanical design principles, electronic component materials, metallurgy, plating, interconnects, composites, harnesses, connectors, construction, thermal interface materials, dielectric materials, and sealing methods
• Ability to translate product requirements into system and subsystem requirements
• Ability to translate subsystem requirements to part requirements, and develop test plans to validate requirement achievement
• Proficiency in CATIA or similar 3D modeling system and at least one battery system modeling/simulation tool suite
• Excellent verbal and written communication skills
• Proactive delivery of communication and follow up
• Excellent organizational skills and attention to detail
• Must have the ability to independently prioritize and accomplish work within time constraints
• Proficiency with Excel VLOOKUP, pivot tables, MS Office Suite

You may also be able to contribute:

• Experience in Altium or equivalent electronic design system preferred

Any offer of employment is conditioned upon the successful completion of a background check. We are an equal opportunity employer and value diversity at our company. We do not discriminate on the basis of race, religion, color, national origin, citizenship, sex, gender, gender expression, sexual orientation, age, marital status, veteran status, disability status or any other category or class protected under applicable federal, state or local law. Individuals with disabilities may request a reasonable accommodation to participate in the job application or interview process, to perform essential job functions, and to receive other benefits and privileges of employment. Please contact us to request accommodation at: ta-support@supernal.aero

This position may include access to certain technology and/or software source code subject to U.S. export controls laws and regulations. If an export authorization from an applicable US regulatory agency is required in connection with your employment, your employment is contingent upon Supernal’s receipt of such regulatory authorization(s) and your continued compliance with all conditions and limitations pursuant to such authorization(s).