Staff Mechanical Engineer (Battery Structural Integrity Analysis Lead)

Job title: Staff Mechanical Engineer (Battery Structural Integrity Analysis Lead)
Location: Gachibowli, Hyderabad
Full-Time/Onsite
Job Description:
 Develop high-accuracy micro and macro scale ANSYS Mechanical / COMSOL / LS-Dyna models for battery structures, weld / adhesive failures, and dynamic fatigue (validated with nCode).
 Predict high quality stress-strain behavior and fatigue life of battery structures.
 Create reduced order models (ROM) to accelerate system simulations.
 Transform FEA insights into optimal designs using DOE and / or optiSLang.
 Material testing and designing of fixtures.
 Resolve structural failures with root cause analysis.
 Identify and define optimal operating zones for Process tools and equipment related to battery design and manufacturing.
 Ensure integrity and safety of battery structure for various quality checks like drop, crush tests etc.
 Understand and improve the raw material supply chain quality and design rules for manufacturability (DFM).
 Integrated modelling of mechanical, thermal and electrochemical aspects involved in battery manufacturing process and/or battery operation.
 Proven technical leadership and ability to handle cross functional roles, project planning / execution and working with operations and executive leadership.
 Decision making under uncertainty, comfortable making high-stake decisions in fast paced research environment.
 Be prepared for occasional travel up to 15% of the time to support production launch and ramp activities, including supplier visits and on-site support at company facilities.
Required Skills & Qualifications:
 Mechanical design mastery: Deep understanding of FEA, thermal, fluid systems, and materials with experience in coding and use of FEA software.
 Familiarity with material testing and equipment / instruments used in such tests.
 15+ years of mechanical engineering experience, with at least 5 years in technical leadership roles.
 Masters or PhD in mechanical engineering or related field.
 Excellent communication: Can clearly articulate complex technical ideas to non-engineers.
 Product lifecycle management: Experience from concept through prototyping and research to mass production.
Preferred Skills:
 Manufacturing knowledge: Familiarity with DFM, supply chain and vendor quality management.
 Systems thinking: Ability to integrate mechanical systems with electrical, firmware and software components.
 Industry – experience solving mechanical engineering problems in battery, micro-electronics, mobiles, MEMS devices is a plus.
 Corrosion and embrittlement assessment is a plus.
 Experience with Computer-Aided Design (CAD) is a plus.