{"id":822676,"url":"https://alion.io/job/brelle-senior-mechanical-design-engineer","title":"Staff Mechanical Design Engineer","company":{"id":670466,"name":"Brelle","domain":"brelle.tech","url":"https://alion.io/company/brelle","size_band":null,"is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Ashby","truth_index":null},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"staff","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Los Alamitos, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":160000,"max":185000,"currency":"USD","period":"year","gross":null,"usd_annual":185000},"salary_estimate":null,"experience_years_min":7,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-01-07T18:41:15Z","employer_posted_date":"2026-01-07","last_verified_at":"2026-10-06T22:00:48Z","board_verified":true,"closed_at":null,"days_open":272,"trust":{"level":"stale","repost_count":0,"flags":["stale"],"days_open":271},"description":"About Brelle\nEnergy for what moves us.\nBrelle 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.\nBrelle 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.\nOur 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.\nOur 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.\nWe’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.\nAbout the Role\nAs a Staff Mechanical Design Engineer, you'll own the design and development of battery module components from concept through production.\nYou'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.\nThis 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.\nWhat You'll Do\nOwn the design for a new module architecture- cell retention systems, thermal management strategies, safety systems, housing integration, and electromechanical interfaces\n\nWork with cylinder and pouch cell formats in 400-1000V systems, optimizing weight, thermal performance, cost, and manufacturing feasibility\n\nCollaborate cross-functionally with Brelle’s electrical, thermal, simulation, and software teams to optimize the complete battery pack package\n\nCoordinate design work with pack team members to converge on feasibility for function, manufacturing, and reliability of modules in pack and vehicle\n\nDevelop a robust cell venting strategy and propagation protection while meeting manufacturing and cost targets\n\nIdentify and suggest missing requirements needed and drive completion of released requirements\n\nWhat We're Looking For\nBachelor's or master's degree in mechanical engineering (or equivalent with demonstrated depth)\n\n7-8+ years of mechanical design experience in automotive or motorcycle battery/powertrain development\n\nAdvanced CAD proficiency in CATIA V5/V6 (3DX), NX, or SolidWorks: complex assemblies, GD&T, production drawings\n\nRobust understanding of lithium-ion cell as it relates to electromechanical and safety design constraints\n\nUnderstanding of battery system architectures and HV safety requirements (400V+ systems)\n\nHands-on structural FEA experience: defining load cases, boundary conditions, interpreting results for design decisions\n\nExperience with DFM for multiple processes: injection molding, stamping, casting, composites, machining, fabricating\n\nExperience with DFMEA/DVP&R cycles and design release processes\n\nBattery module or pack design experience-you've navigated cell-level constraints and thermal management complexity\n\nPreferred Qualifications\nPractical hands-on experience in professional or personal projects - interest in working directly on the parts/products in the lab\n\nThermal simulation experience (CFD or equivalent)-you understand heat transfer, material selection implications and can develop solutions to meet system-level requirements\n\nDesign experience integrating into vehicle platforms-you understand powertrain architecture and integration challenges\n\nExperience working at or with automotive OEMs or Tier-1 Suppliers on electrified platforms.\n\nProven 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\n\nHow We Work\nUnderstand the Problem \nWe take the time to understand what we're actually solving before jumping to the obvious answer.\nOwn What Needs to Happen \nWe take responsibility for outcomes, not just our individual tasks. If something needs to happen, we figure out how to make it happen.\nOptimize for the Team \nWe make decisions with the broader team and company in mind, sharing information and helping each other move faster.\nRefuse the Obvious Answer \nWe challenge assumptions, explore better approaches, and don't accept \"that's how it's always been done.\"\nKeep Your Word \nWe do what we say we'll do. We communicate early when something changes and hold ourselves accountable to our commitments.\nCompensation & Benefits\nBase Salary: $160,000 - $185,000\nMeaningful equity participation through Brelle's Employee Incentive Plan.\nMedical, dental, and vision (HMO/PPO)\n\n401(k)\n\nFlexible PTO\n\nTeam meals twice a week\n\nMonthly team events\n\nBuild something exceptional. Own your work. See it move.\nBrelle is an equal opportunity employer.","description_format":"text","description_chars":5620,"description_truncated":false,"requirements":{"experience_years_min":7,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":false,"languages":[]},"benefits":["Equity"],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Energy Storage","Power Supplies & Power Electronics"],"lifecycle":[{"event":"open","at":"2026-09-12T13:21:35Z"}],"visa":[{"country":"US","licensed_sponsor":true,"evidence":"H-1B filings in 12 months: 2","filings_12m":2,"filings_prev_12m":0,"green_card_filings_12m":0,"median_offered_wage_usd":112500,"route":null,"cap_exempt":false,"checked_at":"2026-10-03T21:08:04+00:00","sources":["US Department of Labor: LCA disclosure data (H-1B, H-1B1, E-3)"],"filings_for_role_12m":0}],"liveness":{"score":9,"band":"cold","label":"Long shot","p_open":1,"p_active":0.334,"p_room":0.28,"age_days":271,"expected_fill_days":30,"reasons":["conf:0","win:tail","crowd:"],"computed_at":"2026-10-06T05:45:30Z"},"pay":{"stated_usd_annual":185000,"is_top_pay":true},"html_url":"https://alion.io/job/brelle-senior-mechanical-design-engineer","json_url":"https://alion.io/job/brelle-senior-mechanical-design-engineer.json","meta":{"generated_at":"2026-10-07T00:07:01Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler","counted_by":"address","units_charged":1,"used_today":106,"day_limit":5000,"remaining_today":4894,"minute_limit":60,"resets_at":"2026-10-08T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":670466},"rest":"https://alion.io/mcp/rest/get_company?id=670466"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fbrelle-senior-mechanical-design-engineer"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fbrelle-senior-mechanical-design-engineer"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fbrelle-senior-mechanical-design-engineer"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/brelle-senior-mechanical-design-engineer\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fbrelle-senior-mechanical-design-engineer"}]}