Lead – Battery Pack R&D;

Reporting to : Head - Battery R&D;

Location : Chennai

Purpose of the Role

Lead the design, development, integration, validation, and industrialization of High Voltage (HV) Battery Packs for Electric Vehicles (EVs) and Energy Storage applications. Responsible for battery pack architecture, cell and BMS selection, virtual validation, testing and homologation, manufacturing feasibility, technical leadership, and resolution of field issues while ensuring compliance with performance, safety, quality, and regulatory requirements.

Key Responsibilities

Technical Leadership

- Lead end-to-end development of HV Battery Packs from concept to SOP.
- Define battery pack architecture, technical roadmap, and design standards.
- Drive battery pack development activities from requirements definition through validation and product release.
- Mentor and guide battery pack engineers and cross-functional teams.
- Establish engineering best practices, design review processes, and product development methodologies.

Battery Pack Design & Development

- Lead design and development of complete HV Battery Pack systems.
- Define system requirements based on vehicle, customer, and regulatory specifications.
- Drive battery pack mechanical, electrical, thermal, and safety design activities.
- Support selection and integration of battery cells, BMS, contactors, fuses, connectors, cooling systems, and safety components.
- Conduct design reviews and ensure design optimization for performance, reliability, safety, manufacturability, and cost.

Virtual Validation & Engineering Analysis

- Lead virtual validation activities for battery pack systems.
- Drive structural, thermal, vibration, durability, and safety simulations.
- Correlate simulation results with physical validation data.
- Recommend design improvements based on CAE and validation findings.




- Establish virtual validation methodologies and engineering standards.

DVP, Validation & Homologation

- Define battery pack Design Verification Plan (DVP) and validation strategy.
- Lead battery pack testing activities including performance, environmental, vibration, abuse, durability, ingress protection, and safety validation.
- Support compliance with AIS 156, AIS 038, AIS 048, CMVR, and relevant automotive standards.
- Coordinate homologation and certification activities with testing agencies and regulatory bodies.
- Ensure all validation deliverables are completed as per program timelines.

Manufacturing & Industrialization

- Provide technical direction for battery pack manufacturing and assembly processes.
- Guide design-for-manufacturing (DFM) and design-for-assembly (DFA) implementation.
- Support pilot builds, manufacturing trials, process validation, and SOP readiness.
- Review supplier capabilities and manufacturing feasibility during product development.
- Drive continuous improvement in product quality, cost, and manufacturability.

Field Quality & Reliability

- Lead investigation and root cause analysis of battery pack field failures.
- Support corrective and preventive actions in coordination with Quality, Service, Manufacturing, and Suppliers.
- Analyze warranty trends and reliability data.
- Drive product improvements to enhance durability, safety, and customer satisfaction.

Stakeholder Management

- Coordinate with Vehicle Engineering, BMS, Testing, Manufacturing, Quality, Procurement, and Supply Chain teams.




- Interface with cell suppliers, BMS vendors, certification agencies, and technology partners.
- Drive project planning, resource allocation, milestone tracking, and risk management.
- Lead technical reviews with internal and external stakeholders.

Qualifications

- B.E./B.Tech or M.E./M.Tech in Mechanical, Electrical, Electronics, Automotive Engineering, or related discipline.
- Preferred: Master's degree in Electric Vehicle Technology, Energy Storage Systems, or Automotive Engineering.
- 8–10 years of experience in EV Battery Pack Development, Automotive R&D;, or Energy Storage Systems.
- Minimum 7 years of experience in HV Battery Pack design and development.
- Experience leading engineering teams and product development programs.

Technical Skills

- HV Battery Pack Architecture and Design.
- Lithium-Ion Cell Technologies and Selection.
- Battery Management System (BMS) Integration.
- Thermal Management Systems.
- Structural, Thermal, and Vibration Simulation.
- Virtual Validation and CAE Tools.
- DVP Planning and Validation Execution.
- Battery Pack Testing and Reliability Engineering.
- Homologation and Regulatory Compliance.
- DFMEA, APQP and Design Reviews.
- Root Cause Analysis and Field Failure Investigation.
- Product Lifecycle Development from Concept to SOP.
- Manufacturing Processes including Sheet Metal Fabrication, Welding, Die Casting, Extrusion, Sealing, and Assembly Technologies.

Preferred Skills

- EV Battery Systems Engineering.
- Functional Safety Awareness (ISO 26262).
- Battery Safety Standards and Regulatory Compliance.
- Knowledge of AIS 156, AIS 038 and Global EV Standards.
- Thermal Runaway Mitigation Strategies.
- Design for Manufacturing (DFM) and Design for Assembly (DFA).
- Supplier Development and Technical Evaluation.
- Project Management and Technical Leadership.

📌 Lead - Battery Pack R&D (Chennai)
🏢 Tracers India
📍 Chennai