Battery Electrical Engineer

As a Battery Electrical Design Engineer you will focus on the design analysis and integration of HV components ensuring the electrical system is optimized for high power density EMI/EMC compliance and rigorous aerospace safety standards. You will be a key contributor to the Energy Storage and Power Systems (ESPS) team driving the electrical architecture from conceptual trade studies to flight-certified hardware.

• Architect HV Power Systems: Define and design the high-voltage distribution architecture including busbars wiring harnesses contactors fuses and power electronics interfaces.
• Design Battery Electrical Systems: Lead the electrical design of battery modules and packs focusing on sensing (voltage/temperature) cell balancing circuits and high-current interconnects.
• Design Battery Charging Systems. Lead the development of on-board and off-board charging systems ensuring compatibility with high-power standards such as CCS MCS and NACS.
• Execute Electrical Analysis: Perform detailed electrical modeling and simulation including power budget analysis voltage drop calculations fault current modeling and thermal-electrical co-simulation.
• Manage EMI/EMC & Shielding: Define grounding and shielding strategies to ensure system compatibility and compliance with aerospace electromagnetic interference standards (e.g. DO-160).
• Drive HV Safety & Protection: Design isolation monitoring interlock circuits (HVIL) and circuit protection schemes to ensure operator safety and system resilience during fault conditions.
• Lead Validation & Testing: Design and oversee electrical verification plans including high-current characterization insulation resistance testing and dielectric withstand (HiPot) validation.

• Technical Lead for HV Systems: Serve as the subject matter expert for electrical physics providing guidance on component selection (e.g. MOSFETs IGBTs contactors) and high-power PCB layouts.
• System-Level Optimization: Conduct trade studies to balance electrical efficiency against mass volume and thermal constraints in the propulsion string.
• Supplier Engagement: Draft technical specifications and Statements of Work (SOW) for HV components and sub-assemblies managing technical deliverables from strategic partners.
• Failure Mode Analysis: Lead electrical Failure Mode and Effects Analysis (FMEA) to identify and mitigate risks such as short circuits arc flashes or insulation breakdown.
• Certification Support: Author technical reports and design descriptions to demonstrate compliance with aviation safety standards (ARP 4754DO-311A DO-160 ARP 4761).

• Education: B.S. M.S. or Ph.D. in Electrical Engineering or a related field.
• Experience: 8 years of experience in electrical design specifically with high-voltage (> 400V) systems in aerospace EV propulsion or heavy transportation.
• General Electrical Mastery:
  • HV Design: Deep expertise in high-power distribution busbar design and creepage/clearance requirements for high-altitude environments.
  • Analysis Tools: Proficiency in SPICE (LTspice/PSpice) MATLAB/Simulink or equivalent tools for transient and steady-state electrical simulation.
  • Sensing & Control: Experience with Battery Management System (Client) hardware including precision voltage/current sensing and isolation circuits.
• Battery Specifics: Applied knowledge of lithium-ion cell electrical behavior state-of-charge (SoC) estimation hardware and cell-balancing architectures.
• Design Tools: Proficiency in ECAD tools (Altium Mentor Graphics or Zuken) and familiarity with MCAD (NX/SolidWorks) for harness and busbar integration.
• Regulatory Awareness: Strong familiarity with aerospace environmental and safety standards (DO-160G DO-311A).
• Communication: Ability to distill complex electrical architectures into clear requirements for software mechanical and systems engineering teams.