Senior Mechanical Design Engineer - Power Systems

Overview

Lightship is the first American all-electric recreational vehicle manufacturer currently developing an aerodynamic, battery-powered trailer for the electric age. As the macro transition to an all-electric transportation ecosystem accelerates, Lightship is bringing the increased convenience and superior performance that electrification offers to a pastime enjoyed by over 11 million American families.

Lightship is committed to hiring and developing top talent from diverse backgrounds. We believe representing and supporting diverse groups is key to the success of our team members, customers, shareholders and the achievement of our mission and vision. We operate in a collaborative environment with a flat organizational structure and expect a high degree of integrity, autonomy and creativity from all members of the team.

As a Senior Mechanical Design Engineer you will serve as a hands on technical lead for multiple power systems sub-systems, primarily our all-electric RV’s Solar System. You will be responsible for continuing developing, prototyping, and testing of the solar arrays, related junction boxes, harnessing, charge controllers and circuit protection. With a small team, you'll also help dive into development on other Power Systems components, including power distribution modules, mounting brackets, electronics enclosures, and selecting off the shelf electronics components.

• Engineering development and requirements generation:
• Work with the Product and Design teams to develop high level product requirements, and create lower level engineering requirements for your sub-systems by working with the various engineering teams (systems, controls/software, vehicle engineering)
• Review regulatory requirements and ensure all components are designed to meet them
• Work with the supply chain and finance teams to ensure all subsystems are meeting cost targets
• Perform Design Failure Modes & Effects Analysis (DFMEA) to highlight reliability and safety issues. Use the outputs of this process to create design fixes and drive test plans
• Create timelines and schedules for all subsystem development and work with the program team to ensure these are meeting high level milestones and development goals
• Create detailed CAD and drawings of all custom components. Work with the CAD/PLM team to ensure all packaging issues are resolved and all parts are released
• Select off the shelf components that meet all functional, durability, cost and quality needs
• Create tolerance stack analyses and apply appropriate GD&T controls to 3D geometries
• Hold design reviews with the cross functional team to ensure all considerations are taken into account
• Host core team meetings to push forward work and collaborate with the cross-functional teams
• Work with supply chain to select appropriate suppliers, and work with suppliers to ensure components can be manufactured by performing detailed design for manufacturing (DFM) analysis
• Testing and analysis:
• Create design validation plans (DVPs) by working with the test engineering team
• Perform all necessary analysis (thermal, structural, etc) to reduce risk of design failures and ensure we meet performance targets
• Build functional prototypes of subsystems to ensure early de-risking before full vehicle builds
• Perform engineering validation (EV) testing of subsystems to characterize performance and safety
• Work with the test engineering team to troubleshoot issues from highly accelerated life testing (HALT) and vehicle level test failures
• Build, production, and aftersales support
• Create work instructions by working with the production operations teams and performing design for assembly (DFA) analysis
• Perform first article inspections of components from suppliers and work with in house quality engineering to triage quality issues
• Support prototype and production builds in Broomfield, CO factory (10-15% of time, depending on the phase of development)
• Support field service engineering of customer vehicles and marketing vehicles

• 5+ years design engineering experience
• Comfortable working in a dynamic environment with shifting priorities and…