Role Summary
The Sr Mechanical Design engineer for BESS is responsible for leading the mechanical architecture, design, analysis, validation, and industrialization of battery racks, enclosures, containers, cooling interfaces, structural frames, and auxiliary mechanical systems used in large-scale energy storage systems. The role ensures structural integrity, manufacturability, thermal compatibility, fire safety, and compliance with global BESS standards. It involves cross-functional leadership across thermal, electrical, safety, and system engineering teams.
Key Responsibilities
- Lead mechanical architecture for utility-scale BESS platforms:
- Battery modules, racks & sub-racks, Enclosures & container structures
- LV/HV panels & wiring harness routing, Cooling ducting & air/liquid flow paths
- Define form factor, layout, and assembly strategy for modular & containerized BESS.
- Balance performance, safety, manufacturability, and cost.
- Review and approve 3D drawing and 2D fabrication drawings
- Create and maintain mechanical BoM, materials selection, and finishing/coating requirements (C5-M/anti-corrosion). Perform detailed mechanical design for metal structures, welded frames, sheet-metal parts, brackets, and enclosure assemblies.
- Lead structural FEA for static, dynamic, vibration, fatigue, seismic, and transportation loads.
- Ensure compliance with global mechanical standards
- Validate lifting points, load paths, shock resistance, and mechanical clearances.
- Collaborate with thermal engineering to integrate HVAC / liquid cooling, Duct routing, Heat exchangers, Sensor placement, Venting & airflow optimization
- Work with electrical teams to ensure proper placement of HV/LV cabinets, busbars, grounding points, and cable trays.
- Integrate fire detection, suppression, and venting mechanisms (e.g., FACP, smoke ducts, deflagration panels).
- Ensure compliance with UL 9540A mechanical and venting requirements.
- Lead prototype builds for racks and container systems.
- Define mechanical test plans: vibration, shock, thermal cycling, ingress protection (IP55/65), corrosion, salt spray.
- Conduct field validation for installation, maintenance access, and cable routing feasibility.
- Evaluate issues from field returns—fatigue failures, alignment issues, corrosion, sealing failures, etc.
- Ensure all mechanical standards are complied.
- Support manufacturing teams Tooling, jigs & fixtures, Weld & fabrication process selection Assembly line setup, Takt time and manufacturability improvements
- Support supplier qualification for racks, sheet metal, and enclosure components.
- Drive cost-optimization without compromising structural safety.
- Closely Work closely with System engineering, Electrical design team, Thermal engineering, Safety engineering, Program management, Supply chain & manufacturing, Drive design reviews, DFMEA, PFMEA, and issue resolution.
- Mentor junior engineers and guide design best practices.
Required Qualifications
Bachelor’s or Master’s in Mechanical Engineering, Mechatronics, Structural Engineering, or related disciplines.
Technical Skills
- Expertise in 3D CAD (SolidWorks, CREO, CATIA, Siemens NX).
- Strong understanding of sheet-metal design, welded structures, and modular assemblies.
- Experience in FEA tools (ANSYS, Abaqus) for structural analysis.
- Knowledge of thermal interfaces, air/liquid cooling integration, and ventilation design.
- Familiarity with fire suppression hardware and venting mechanisms.
- Understanding of lithium-ion safety, HV clearances, and BESS mechanical standards.
Experience
- 8-12+ years in mechanical design for BESS, EV battery packs, UPS enclosures, energy storage containers, or industrial equipment.
- Exposure to utility-scale containerized BESS preferred.
- Field commissioning or field troubleshooting experience is a plus.
