A123 Systems LLC

Module Development Engineer

3 weeks ago
# of Openings


A123 Systems has an immediate opening for a Product Mechanical Engineer with automotive product development background. This person will be responsible for the design, development, release and validation of prismatic battery modules and packs within a Li-Ion Battery System for hybrid and electric vehicle applications. Focus of the position will be to take the lead role in design, development and sample build in a manufacturing and assembly friendly manner from concept through production.


  • Generate innovative detailed design concepts
  • Create and maintain bill-of-material for products in Pro-E and Agile.
  • Check part and assembly drawings, perform tolerance stack up analysis and implement GD&T on assembly and part drawings as necessary
  • Create and release assembly and functional test specifications related to battery assemblies
  • Interface with other groups such as manufacturing, quality and supply chain to ensure synergy and multifunctional input.
  • Interface with prototype and production manufacturing teams to ensure DFM, Product BOMs, tolerances, SC’s and CC’s are being met. Support activities related to measurement of SCs and CCs
  • Lead root cause analysis and make design improvements as necessary
  • Plan design of experiment plan and perform data analysis to achieve maximum effectiveness of trials, outcome data, and analysis
  • Hands on aptitude with the ability to assemble concept and prototype level parts
  • Participate in internal and external product application specific meetings.
  • Understand and adhere to program timelines and APQP deliverables.
  • Initiate product design improvement plans
  • Drive strict adherence to change management disciplines (change request ECs, version control, change validation and release).
  • Create and update DFMEAs and DVPRs as required.
  • Drive closed-loop handling of all issues to ensure continuous improvement and to prevent recurrence of failures.


  • BSME or a degree in related engineering discipline required.
  • 3+years of experience in automotive engineering environment is needed
  • 3+ years of experience in mechanical and electromechanical component and assembly design, development and part release is required.
  • Experience with Creo or Catia preferred (in the following areas: Assembly design/packaging, drafting)
  • Proficient in GD&T and tolerance stack-up calculation.
  • Hands on experience with Quality & Reliability disciplines (FMEAs, APQP)
  • Practical experience with batteries or electromechanical parts from the mechanical engineering perspective is desired
  • Proficient in MS Office (MS Word, MS Excel and MS PowerPoint)
  • Hands on aptitude with building concept prototypes and during root-cause analysis
  • Working experience in Minitab and IQFMEA is preferred
  • Experience with electrical and mechanical interfaces is preferred (connectors, mechanical aspect of PCBs, flex circuits, wire-harnesses, fuses, plastic parts, stamped metal parts, plating specifications, laser welding)
  • Sound background in mechanical engineering mechanics and methods is a must
  • Practical experience in engineering of materials is necessary (Polymers, Metals, Composites and Engineered materials)


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