Senior Mechanical Sustaining Engineer

Job Summary

The Senior Mechanical Sustaining Engineer is responsible for the ongoing design, development, and execution of core battery mechanical system components and assemblies of existing American Battery Solutions (ABS) products. The individual will be responsible for defining, documenting, and designing battery pack and battery module mechanical and thermal components and assemblies, and overseeing validation of those components and assemblies.

This role requires the ability to apply technical knowledge to innovative designs, driving resolution of challenges, and take ownership of product development and sustaining activities.

• Serve as component owner and primary technical contact for battery systems post‑Safe Launch, ensuring long‑term product reliability and performance.
• Lead root cause analysis and resolve issues arising from customer field reports, production quality concerns, and supplier defects.
• Collaborate cross‑functionally with Manufacturing, Quality, Service, Program Management, and Supplier teams to drive effective issue closure and implement corrective actions.
• Apply technical expertise to ensure the on‑time delivery of work products throughout the product development life cycle for each project.
• Own the design and development of efficient designs for components and sub‑assemblies, working closely with manufacturing engineers to develop processes and tools that support manufacturing and assembly, while driving continuous improvement initiatives to enhance product performance, reduce costs, and improve manufacturability.
• Perform component definition, sizing, selection, and design of battery module and pack mechanical and thermal components, including battery structures, enclosures, injection‑molded plastics, cooling plates, and mechanical joining methods.
• Collaborate with Systems Engineers and CAE Engineers to validate design concepts prior to battery pack prototype builds.
• Contribute to mechanical system Design Failure Mode and Effects Analysis (DFMEAs), Process Failure Mode and Effects Analysis (PFMEAs), Design Verification Plans and Reports (DVP&Rs), and Product and Process design reviews.
• Lead supplier evaluation and development for assigned commodities in collaboration with purchasing for existing products.
• Support prototype system builds by ensuring timely delivery of parts and resolving issues promptly.
• Ensure compliance with federal and state regulations as well as all company policies, processes, and procedures.

• Education:
  
  Bachelor* – Mechanical Engineering or a related engineering field of study.
• Experience:
  
  Five* (5) years in the position above, as a Mechanical Engineer, Battery Cell Engineer, Design and Release Engineer, or in a related mechanical engineering role;
• Of the five (5) years of experience, four (4) years of experience must include:
• 1. High Voltage (>350V) electrification product design and development;
• 2. CAE modeling, including interpreting boundary conditions, assumptions, and model limitations;
• 3. Data processing and statistical analysis.
• Will accept equivalent foreign degree. Will accept a graduate degree in above major fields of study and three (3) years of full‑time relevant work experience; will also accept any fully equivalent combination of education, training, and/or experience.

• Decision Making & Analysis:
  Makes sound decisions based upon a mixture of data‑driven analysis, expertise, experience, and judgment; collects relevant information, seeks input from others, and identifies connections and/or root causes of problems.
• Takes Initiative:
  Exhibits strong drive for results and success; conveys a sense of urgency and drives issues to closure; persists despite obstacles and opposition.
• Continual Improvement:
  Displays a consistent orientation toward producing the highest quality products or services, while keeping a focus on sustainability. Constantly looking for incremental improvements in work processes and results.
• Delivers Results:
  Achievement oriented, feeling a sense of urgency to reach goals on time, if not before.
• Assertiveness:
  Maintaining a position when you know you are right; standing up to others and…