Mechanical Engineer - Battery Pack, Satellites (Starlink)
Core
Design and develop high-voltage battery packs for Starlink satellites, integrating thousands of 2170-format cylindrical cells to maximize energy density and ensure reliable operation in Low Earth Orbit.
Role type
Mechanical Engineer (Battery Pack Design)
Builds
Satellite battery packs for Starlink constellation
Domain
Aerospace / Satellite Systems / Energy Storage
Deliverable
production ML models | product features | dashboards & analysis | research | client delivery | infrastructure | physical/clinical work -> product features (battery packs)
Required skills
CAD design, FEA analysis, battery pack design, 2170-format cell integration, DFMEA, root-cause analysis, qualification testing (vibration/thermal/vacuum), manufacturing process development, GD&T
Preferred skills
NX, ANSYS, FEMAP, design of experiments, statistical process control, PCB mechanical design, high-volume production ramp experience
Technologies
NX, ANSYS, FEMAP, CAD, FEA
Responsibilities
Design satellite battery packs integrating thousands of 2170-format cells; Perform CAD & analysis of mechanical, electrical, and thermal performance; Drive design trades to maximize Wh/kg and minimize $/kWh; Conduct DFMEAs and root-cause analyses; Validate designs via qualification testing; Develop efficient in-house production processes; Collaborate with manufacturing, cell, and software teams.
Seniority
Entry to Mid-level (1+ years experience required)