Mechanical Structural Engineer E+ES (Battery and Power systems)

Role Overview

Mechanical Structural Engineer responsible for design, analysis, and product realization of battery systems and power electronics for energy and power applications. The role focuses on ensuring structural integrity, electrical packaging compliance, vibration robustness, and manufacturable designs under defined loading conditions, thermal environments, and boundary constraints.

Key Responsibilities
- Structural Design Analysis:
- Define load cases and boundary conditions based on vibration inputs, shock events, G-loads, and operating conditions
- Perform linear and nonlinear FEA: static, modal, random vibration (PSD), fatigue, thermo-mechanical, and drop impact analysis
- Evaluate handling scenarios including lifting and transportation loads as per standards
- Design sheet metal, Casting and Extrusion based structures
- Execute weld design considering fatigue strength, HAZ effects, and distortion
- Perform bolted joint analysis (preload, clamp retention, fatigue, sealing compression)




- Develop isolation mount (iso-mount) models for vibration isolation and resonance control
- Incorporate thermal solutions including Coolant pipes, HV-LV harnessing and auxiliary systems in the design keeping serviceability in mind
- Packaging Electrical Integration:
- Develop 3D packaging layouts considering space claim, clearances, and serviceability
- Define creepage and clearance distances for high-voltage systems in compliance with applicable standards
- Ensure compliance with electrical insulation, dielectric spacing, and safety requirements (IEC/UL/ISO)
- Incorporate EMI/EMC considerations, sealing (IP ratings), and thermal paths in packaging
- Work with electrical teams with intermediate-level exposure to harness design including routing constraints, bend radii, connector interfaces, and protection requirements
- Optimize packaging for thermal dissipation and structural support

Design Definition Con

📌 Mechanical Structural Engineer E+ES (Bengaluru)
🏢 Caterpillar
📍 Bengaluru