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Responsibilities
- Redesign a 300A brass battery terminal to achieve a target weight reduction from 83.75g to approximately 57g without compromising performance
- Develop optimized 3D CAD models and detailed 2D drawings, including GD&T, material, and plating specifications
- Provide DFM recommendations for forging, stamping, or CNC production processes
- Conduct electrical and thermal FEA to assess current flow, temperature rise, and short-circuit forces
- Generate a derating curve and prototype validation plan covering thermal soak, contact-resistance, torque, and vibration testing
- Prepare a comprehensive design report summarizing test targets, validation results, and a comparison of weight and cost versus the current design
- Proven experience in high-current connector design (≥200A), preferably for EV or energy storage applications
- Proficiency in 3D solid modeling using SolidWorks, Inventor, or Creo
- Advanced skills in FEA tools such as ANSYS, COMSOL, or SolidWorks Simulation
- Strong understanding of material selection and plating (brass/copper with nickel or tin finish)
- Familiarity with UL 1973 and IEC 62619 standards for battery safety and performance
- Ability to create detailed engineering drawings with GD&T and manufacturing specifications
- Experience with DFM for forging, stamping, and CNC processes
- Excellent analytical, problem-solving, and technical communication skills
- Ability to deliver thorough documentation, including validation plans and design reports
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