Sr. Mechanical Design Engineer, Powertrain Integration

at  Supernal

Rise above. Are you ready to take human possibility to a new dimension with us?
Supernal is an Advanced Air Mobility (AAM) company that’s developing an electric vertical take-off and landing (eVTOL) vehicle and the ground-to-air ecosystem to support the emerging industry. By creating a sustainable, integrated, and human-centered ecosystem, we are committed to taking a thoughtful and responsible approach to entering the AAM market with a product that meets the high level of safety and reliability in today’s air transportation system.
The future of mobility starts with people. We believe in creative thinking and collaboration to help build a better mobility experience for everyone, improving people’s ability to move – whether for work or play. Join our dynamic team as we strive to be a part of something greater where potential powers tomorrow!
Supernal provides an inviting open-space workplace designed to foster collaboration, which aligns with one of our core values. This position is required to work on-site 5 days a week.

WHAT WE DO:

The Battery Pack Team is responsible for designing and prototyping high-voltage and high-power battery systems in electrified aircraft. The electronics packaging engineer for battery pack design is critical to the Energy Storage System (ESS) development process, including conceptual designs, components selection, prototype builds, and launch designs for volume manufacture.
The Sr. Mechanical Design Engineer, Battery Electronics Packaging, will design the mechanical aspects of electrical components and their packaging. The Electric Vertical Take-Off and Landing (EVTOL contains high-voltage printed circuit boards, flex circuits, cable harnesses, laminated bus bars, and sense circuits. The main responsibility of this role will be to plan and ensure the protection of these electronic components in the Supernal battery pack designs.

• Drive mechanical design of electrical components, interconnects, and electromechanical subsystem designs from conceptual and requirements development through production
• Select, prove, and implement the application of existing technologies to internal product development and develop new technologies to improve product metrics; for electromechanical components, this may include interconnects (solder bonds, welds, ribbon bonds, connectors, terminal lugs, spring fingers, etc.) and packaging interfaces (PCBA layup, flex layup, layout, vias, bolted mounts, heat stakes, over molding, snap fits, thermal interface materials, heat sink interfaces, harness insulation, shielding, strain relief, and cable management, etc)
• Provide technical expertise and mentorship to the team in electronics packaging and mechanical design of electronic components, such as wire harnesses, flexible printed circuit boards, connectors, laminated bus bars, and voltage, current, and temperature sense technologies
• Define specifications pertaining to electronic components (dimensional and dielectric, functional, performance, reliability, survivability, component manufacturing, and interface manufacturing
• Perform fundamental prototyping, testing, and analysis tasks and provide assistance for advanced analysis and validation testing
• Identify the root cause of issues in prototype, validation, and production stages and help in finding solutions for them
• Communicate work progress to department leadership through written and live updates, representing both individual and team efforts
• Collaborate with teams at Supernal sites and meet with suppliers for technology development, process validation, and issue resolution
• Build relationships with critical multi-functional teams in electrical design, testing, safety, abuse, manufacturing, systems, certification, and airframes
• Partner with PMO organization to implement build plan
• Up to 10% of domestic and international travel
• Other duties as assigned