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About the Role

We’re seeking a passionate and dedicated Battery Pack Design Engineer who brings enthusiasm and expertise to the table. In this role, you’ll lead the architecture, design, component selection, development, validation, and launch of lithium-ion battery packs and modules. This role will play a key part in the design and development of battery systems, contributing to battery structures, module packaging, thermal management systems, electrical isolation features, safety-critical components, and enclosure assemblies from concept through production release. Working closely with cross-functional engineering, manufacturing, validation, and supplier teams, the successful candidate will help define and execute robust design solutions that meet performance, safety, reliability, manufacturability, and cost objectives. The ideal candidate brings strong battery design expertise, systems-thinking capability, and hands-on product development and manufacturing experience, with the ability to influence technical direction and drive subsystem-level design decisions within a collaborative team environment. We value innovative and creative ideas—yes, even during meetings (where snacks are always welcome). If you enjoy tackling challenges with positivity and a bit of humor, you’ll feel right at home here.

Responsibilities

Lead the mechanical design and development of battery modules and battery packs for material handling equipment from concept through production launch.
Own battery module and pack architectures such as structural components, cell retention systems, compression mechanisms, cooling systems, electrical isolation features, busbar integration, and serviceable assemblies.
Develop innovative solutions balancing performance, cost, mass, manufacturability, thermal performance, durability, and safety.
Create and release production-ready CAD models, engineering drawings, specifications, and BOMs.
Perform packaging studies and trade-off analyses for battery cells, modules, cooling systems, safety-critical components, and supporting structures.
Drive Design for Manufacturing (DFM), Design for Assembly (DFA), and serviceability initiatives throughout the product development cycle.
Collaborate with electrical, BMS, systems, and thermal engineering teams to ensure successful integration of mechanical and electrical subsystems.
Support structural, thermal, vibration, shock, abuse, and environmental validation activities.
Develop and maintain DFMEAs, DVP&Rs, Engineering Specifications, Statements of Work, and supplier technical requirements.
Lead engineering prototype builds, design verification activities, root cause investigations, and corrective action implementation.
Conduct tolerance stack-up analyses and apply GD&T best practices to ensure robust production designs.
Work directly with suppliers on component development, tooling feasibility, APQP activities, and production readiness reviews.
Support battery pack safety strategies including thermal runaway mitigation, electrical isolation, ingress protection, and compliance requirements.
Identify technical risks early and develop mitigation plans to ensure successful program execution.
Support manufacturing launch activities and transition designs into volume production environments.

Requirements

Bachelor’s degree in Mechanical Engineering or related engineering discipline.
10+ years of product development experience with demonstrated success launching complex electromechanical systems into production.
5+ years of direct experience designing lithium-ion battery modules, battery packs, or high-voltage energy storage systems.
Strong understanding of battery cell technologies, module architectures, pack integration, and energy storage system design.
CAD proficiency using Creo, CATIA, NX, or equivalent 3D modeling software.
Strong knowledge of GD&T, tolerance analysis, and engineering drawing standards.
Experience with battery enclosure design, structural components, sealing systems, electrical isolation, and thermal management systems.
Familiarity with manufacturing processes including castings, stampings, extrusions, sheet metal, plastics, machining, and assembly operations.
Experience supporting prototype builds, validation testing, production launches, and supplier development activities.
Working knowledge of CAE tools supporting thermal, structural, vibration, and durability analysis.
Experience developing DVP&R, DFMEA, PFMEA, Engineering Specifications, and APQP deliverables.
Strong technical communication and cross-functional leadership skills.
Ability to work effectively in fast-paced product development environments.
Direct ownership of battery module or battery pack designs that successfully launched into production.
Experience with cylindrical, prismatic, or pouch cell packaging architectures.
Expertise in battery cooling systems including liquid, refrigerant, or air-cooled designs.
Experience with cell compression systems, busbar integration, HV interconnects, and electrical isolation strategies.
Knowledge of battery abuse testing, thermal runaway containment, propagation mitigation, and safety design principles.
Experience developing systems compliant with UL, IEC, SAE, ISO, and UN38.3 requirements.
Familiarity with battery manufacturing processes, module assembly lines, and pack production systems.
Hands-on prototype build experience and comfort working directly with hardware in the lab and on the manufacturing floor.
Experience supporting innovation and advanced concept development.

Skills

Battery Pack Design
Lithium-ion Battery Design
Mechanical Design
CAD (Creo, CATIA, NX)
GD&T
Tolerance Analysis
DFM/DFA
Thermal Management Systems
Electrical Isolation
Structural Analysis
Validation
DFMEA
DVP&R
APQP
Technical Communication
Cross-functional Leadership

Location

Rochester, NY

Work Type

In-person
Full-time

Experience Level

10+ years of product development experience
5+ years of direct experience designing lithium-ion battery modules, battery packs, or high-voltage energy storage systems

Education Level

Bachelor’s degree in Mechanical Engineering or related engineering discipline

Salary/Compensations

$133,605 - $171,290 per year

Benefits

Relocation assistance
Competitive Salary
Performance Bonus
Generous Paid Time Off
13 Paid Holidays
Affordable Medical plans
No-cost Dental & Vision options
100% 401(k) match up to 6%
Company-Paid Life Insurance
Company-Paid Short-Term Disability
Company-Paid Long-Term Disability
Tuition Assistance Program
Employee Assistance Program (EAP)
Recognition and Kaizen Reward Programs
Meaningful opportunities for personal and professional development
Best in class work culture

About the Company

Toyota Material Handling North America (TMHNA) is the industry leader in forklift sales, comprising two main brands: Toyota Material Handling and The Raymond Corporation.
We believe investing in the best people, products, and processes will fuel our future success, and we will always be driven by our foundational principles of “respect for people” and “continuous improvement”.
With opportunities across North America, we are confident you will find the right position within TMHNA that can help you build a long, fulfilling career.