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

We are seeking a Battery Pack Mechanical Hardware Development Engineer II to join our Drone Electric Propulsion Subsystem (EPS) team. In this role, you will be a significant and autonomous contributor, solving difficult hardware engineering problems related to battery systems. You will design, develop, and validate battery packs from concept through production, working on high-voltage battery systems that push the boundaries of performance, reliability, efficiency, and safety.

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 & Development:

•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.

Basic Qualifications

• Bachelor's degree in mechanical engineering or equivalent
• 4+ years of working in mechanical engineering or equivalent experience
• Demonstrated experience taking a mechanical design from concept through prototype to production.
• Battery pack mechanical design: cell-to-pack architecture, module design, cell holders, busbar integration, enclosures, and structural support for prismatic, cylindrical, or pouch cells.
• CAD proficiency: SolidWorks, Creo, CATIA, or NX for 3D modeling, GD&T, and detailed drawings.
• Sealing and enclosure design: IP-rated enclosures, gaskets, potting/encapsulation, and pressure equalization/venting.
• Understanding of high-voltage safety practices, creepage and clearance requirements, and isolation/insulation coordination.
• Familiarity with thermal runaway mitigation and propagation prevention (venting, barriers, intumescent materials).
• Interface knowledge with the BMS (Battery Management System), contactors, fuses, HVIL (high-voltage interlock loop), and service disconnects.
• Awareness of cell chemistry behavior and how it drives mechanical/thermal requirements.
• DFM/DFA (design for manufacturing and assembly), and experience with joining methods relevant to packs (laser/ultrasonic/resistance welding, adhesives, fastening).
• Tolerance analysis and experience working with suppliers on tooling, injection molding, sheet metal, die casting, or extrusions.
• Prototyping, bring-up, and validation testing (environmental chambers, vibration tables, HALT/HASS).
• DFMEA and design-for-safety methodology.
• Familiarity with PLM systems and engineering change management.
• Soft Skills & Cross-Functional Collaboration
• Strong collaboration with electrical, BMS/firmware, systems, safety, and manufacturing teams.
• Requirements definition, design reviews, and clear technical documentation.
• Root-cause analysis and structured problem solving (8D, DMAIC, fishbone).

Preferred Qualifications

• Master's degree in mechanical engineering or equivalent
• 3+ years of working in mechanical engineering or equivalent experience
• Thermal management: designing cooling systems (liquid cold plates, air cooling, phase-change or immersion), thermal interface materials, and managing heat generation/dissipation across the pack.
• Structural/mechanical analysis: FEA for stress, vibration, shock, and drop; tolerance stack-up analysis.
• Experience in automotive, aerospace, marine, or grid-storage battery systems.
• Scripting/simulation tools (MATLAB, Python) for design automation or thermal modeling.
• Experience with fast-charge thermal design and high-C-rate applications.

Amazon is an equal opportunity employer and does not discriminate on the basis of protected veteran status, disability, or other legally protected status.

Our inclusive culture empowers Amazonians to deliver the best results for our customers. If you have a disability and need a workplace accommodation or adjustment during the application and hiring process, including support for the interview or onboarding process, please visit https://amazon.jobs/content/en/how-we-hire/accommodations for more information. If the country/region you’re applying in isn’t listed, please contact your Recruiting Partner.

The base salary range for this position is listed below. Your Amazon package will include sign-on payments and restricted stock units (RSUs). Final compensation will be determined based on factors including experience, qualifications, and location. Amazon also offers comprehensive benefits including health insurance (medical, dental, vision, prescription, Basic Life & AD&D insurance and option for Supplemental life plans, EAP, Mental Health Support, Medical Advice Line, Flexible Spending Accounts, Adoption and Surrogacy Reimbursement coverage), 401(k) matching, paid time off, and parental leave. Learn more about our benefits at https://amazon.jobs/en/benefits.

USA, WA, Seattle - 117,300.00 - 160,000.00 USD annually