Senior Mechanical Design Engineer
Confirmed on the employer's own hiring board on Oct 2, 2026. First seen by Alion on Jan 7, 2026.
About Brelle
Energy for what moves us.
Brelle is a venture-backed technology company building the next generation of energy and powertrain systems for the world’s most demanding machines. Our team comes from companies like Rivian, SpaceX, and McLaren, bringing deep expertise in high-performance engineering, electrification, and advanced manufacturing.
Brelle develops frontier technology that pushes what’s possible in electrified performance. Based in California, we develop next-generation energy and powertrain technology for supercars and superbikes, working alongside leading high-performance brands across the U.S. and Europe.
Our innovations are built on a novel pack architecture, a full-stack software platform, and an advanced approach to automated production. Joining Brelle means working on technology that makes the world’s most demanding vehicles and aircraft lighter, safer, more engaging, and capable of charging in minutes.
Our engineering teams operate like small Skunkworks teams: nimble, cross-functional, and highly technical. Engineers are encouraged to explore new concepts and materials, move quickly from concept to prototype, and have significant autonomy to develop, validate, and release their work across programs.
We’re building something ambitious in a highly competitive market, and the bar is high. We need people who are exceptional at what they do, take real ownership, and are willing to do what the moment requires.
About the Role
As a Senior Mechanical Design Engineer, you'll own the design and development of battery module components from concept through production.
You'll work across cell retention, thermal management, safety systems, housing integration, and electromechanical interfaces, partnering closely with electrical, thermal, simulation, and software teams to optimize the complete battery pack and vehicle package.
This is a hands-on, high-ownership role where you'll be expected to make sound design decisions, solve complex problems, and drive your work forward with a high degree of autonomy.
What You'll Do
Own the design for a new module architecture- cell retention systems, thermal management strategies, safety systems, housing integration, and electromechanical interfaces
Work with cylinder and pouch cell formats in 400-1000V systems, optimizing weight, thermal performance, cost, and manufacturing feasibility
Collaborate cross-functionally with Brelle’s electrical, thermal, simulation, and software teams to optimize the complete battery pack package
Coordinate design work with pack team members to converge on feasibility for function, manufacturing, and reliability of modules in pack and vehicle
Develop a robust cell venting strategy and propagation protection while meeting manufacturing and cost targets
Identify and suggest missing requirements needed and drive completion of released requirements
What We're Looking For
Bachelor's or master's degree in mechanical engineering (or equivalent with demonstrated depth)
5+ years of mechanical design experience in automotive or motorcycle battery/powertrain development
Advanced CAD proficiency in CATIA V5/V6 (3DX), NX, or SolidWorks: complex assemblies, GD&T, production drawings
Robust understanding of lithium-ion cell as it relates to electromechanical and safety design constraints
Understanding of battery system architectures and HV safety requirements (400V+ systems)
Hands-on structural FEA experience: defining load cases, boundary conditions, interpreting results for design decisions
Experience with DFM for multiple processes: injection molding, stamping, casting, composites, machining, fabricating
Experience with DFMEA/DVP&R cycles and design release processes
Battery module or pack design experience-you've navigated cell-level constraints and thermal management complexity
Preferred Qualifications
Practical hands-on experience in professional or personal projects - interest in working directly on the parts/products in the lab
Thermal simulation experience (CFD or equivalent)-you understand heat transfer, material selection implications and can develop solutions to meet system-level requirements
Design experience integrating into vehicle platforms-you understand powertrain architecture and integration challenges
Experience working at or with automotive OEMs or Tier-1 Suppliers on electrified platforms.
Proven track record releasing components to production: you've worked in a high-pace environment, participated in design reviews, and understand how designs move from concept to production level parts
How We Work
Understand the Problem
We take the time to understand what we're actually solving before jumping to the obvious answer.
Own What Needs to Happen
We take responsibility for outcomes, not just our individual tasks. If something needs to happen, we figure out how to make it happen.
Optimize for the Team
We make decisions with the broader team and company in mind, sharing information and helping each other move faster.
Refuse the Obvious Answer
We challenge assumptions, explore better approaches, and don't accept "that's how it's always been done."
Keep Your Word
We do what we say we'll do. We communicate early when something changes and hold ourselves accountable to our commitments.
Compensation & Benefits
Base Salary: $140,000 - $175,000
Meaningful equity participation through Brelle's Employee Incentive Plan.
Medical, dental, and vision (HMO/PPO)
401(k)
Flexible PTO
Team meals twice a week
Monthly team events
Build something exceptional. Own your work. See it move.
Brelle is an equal opportunity employer.