HV Battery Design & Release Engineer- Busbar-to Cell Welding/Array & Thermal

Join the HV Battery Array team as a Design & Release Engineer. You will design, validate, and release high voltage (HV) battery array modules and work closely with cross-functional and global partners to bring them to production. You will also help establish Ford's new in-house laser welding capability for HV battery cells.

Responsibilities:

• Work with CAD designers, CAE engineers, HV battery package engineers, suppliers, welding process engineers, and HV battery component engineers to design and release HV battery welded array modules.
• Develop and ensure compatibility of the electrical, mechanical, and thermal interfaces of the module within the HV Battery System.
• Design or evaluate supplier designs of specific module components.
• Work closely with other functions and global teams to meet package, performance, and attribute requirements for the HV Battery Array/Cell Block System.
• Ensure Design and Release activities are followed and completed.
• Interface with adjacent teams, including the HV Battery unit team, HV Battery manufacturing team, HV Battery cell team, HV Battery Testing team, Supplier Technical Assistance, and Purchasing.
• Identify process and design improvements for efficiency and cost savings.
• Report design, testing, timing, and quality issues to leadership on a timely basis and lead technical resolution.

Laser Welding Focus Area:

• Own and develop the engineering specification for busbar-to-cell laser welding.
• Define the functional requirements of the welded joint for structural integrity, electrical conductivity, and thermal management.
• Develop and execute Design Validation (DV) and Process Verification (PV) test plans to support PPAP of the process assembly line.
• Work with BME to develop capability studies that prove the specification is met.
• Support early plant trials and pre-production builds, including on-site work at the plant.

Qualifications:

• B.S. in Engineering (Mechanical, Electrical, Materials, or Welding Engineering) with 5+ years of relevant experience, OR M.S. in Engineering (Mechanical, Electrical, Materials, or Welding Engineering) with 2+ years of relevant experience
• Relevant experience is in electrified powertrain or HV battery engineering systems, HV battery array design and release, or welding/joining process engineering.
• Experience in Design and Release roles, supplier management, and multi-discipline engineering in electrification
• Experience writing requirements and engineering specifications, and evaluating supplier designs against them
• Experience developing and evaluating DVP&R, DV and PV test plans
• Experience with the Failure Mode Avoidance (FMA) process and quality documents (DFMEA, PFMEA, control plans, etc.)
• Knowledge of GD&T standards, 2D prints, and tolerance stack-up analysis methods
• Strong presentation and communication skills to report to Managers, Chief Engineers, Directors, and New Model Launch Leaders
• Ability to work effectively across the functions of a vehicle program and to interact with multiple internal and external stakeholders, including negotiating tradeoffs
• Proactive, self-motivated, and detail-oriented
• Strong teamwork, organizational, oral, and written communication skills
• Willingness to travel as needed for plant support and design reviews