Battery Pack Mechanical Design Engineer II, Amazon Prime Air - Electric Propulsion Subsystem

• This position requires an engineer who demonstrates strong technical depth in battery pack design while also exhibiting the system-level thinking and influence characteristic of our most impactful contributors.
• Key job responsibilities
• Design mechanical architecture for high-voltage Li-Ion battery packs, including cell arrangement, modules, enclosures, structural supports, and interconnections.
• Create detailed 3D models and manufacturing drawings using CATIA with GD&T.
• Develop cell-to-module and module-to-pack packaging concepts balancing energy density, safety, and manufacturability.
• Design and integrate thermal management systems and sealed, IP-rated enclosures.
• Analysis & Validation
• Perform FEA (structural, vibration, thermal) and tolerance stack-up analysis to validate designs.
• Plan and execute prototype builds, validation testing, and root-cause failure analysis.
• Safety & Compliance
• Design to high-voltage safety requirements including creepage/clearance, isolation, and HVIL.
• Incorporate thermal runaway mitigation and ensure compliance with applicable standards (UN 38.3, UL 2580, IEC 62133, etc.).
• Develop verification test plans to verify designs against DO-160 and DO-274 standards
• Support DFMEA and design-for-safety activities.
• Cross-Functional Collaboration
• Partner with electrical, BMS, systems, and safety engineers on mechanical and interface requirements.
• Coordinate with manufacturing, supply chain, and suppliers on DFM/DFA, tooling, and sourcing.
• Participate in and present at design reviews.
• Documentation & Process
• Maintain engineering documentation and manage changes through PLM.
• Support project planning with estimates, timelines, and risk assessments.
• Continuous Improvement
• Identify opportunities to improve cost, weight, safety, and manufacturability.
• Contribute to team design standards and best practices.

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