Mechanical Design Engineer

What to Expect

We build electric motorcycles. The engineering underneath them needs to be as deliberate, reliable, and honest as the ride itself - and this role is central to making that true. The Mechanical Design Engineer IV is an autonomous technical contributor and practitioner who drives component and system-level development without requiring design guidance or mentoring. Operating from Zero's Netherlands office, this engineer leads mechanical design work across powertrain enclosures, high-voltage (HV) battery pack mechanical systems, vehicle structures, and cross-functional system integration - collaborating directly with programme management, industrial design, supply chain, and OEM (Original Equipment Manufacturer) partners. At this level, the engineer is a practitioner others learn from: technically deep, methodical in decision-making, and highly effective at translating system requirements into production-ready hardware.

Key Responsibilities

Technical Leadership & Design Ownership

• Leads design and development of complex motorcycle components and systems - including structural frames, battery enclosures, IP-rated sealing systems, and powertrain integration - through all programme phases (concept, F&D (Feasibility and Definition), D&R (Durability and Refinement), VAL (Validation), FPCS (First Production Conforming Sample))

• Owns the full technical definition of assigned line items: 3D CAD master models, GD&T drawings, DFM/DFA analysis, DFMEA facilitation, DVP&R (Design Verification Plan and Report) planning, and production release in SAP ECTR

• Drives design decisions independently using sound engineering judgement; communicates trade-offs and recommendations clearly to programme leads and management

• Leads design reviews at key programme gates; prepares and presents technically rigorous review packages, incorporating cross-functional feedback effectively

• Identifies and resolves critical path risks in design and integration; escalates unresolvable conflicts with full technical framing

Battery Pack & High-Voltage Mechanical Integration

• Leads mechanical design of HV battery pack structural and sealing systems, including enclosure design, thermal interface material (TIM) specification, module retention, and bus bar / interconnect packaging

• Defines mechanical interface requirements between the pack and vehicle structure, BMS (Battery Management System) electronics, cooling circuits, and regulatory compliance hardware

• Applies knowledge of UN 38.3 (transport testing), IEC 62619 (safety requirements for stationary and traction batteries), and relevant homologation standards (EU Type Approval, AIS-156 for India-market programmes where applicable) to design decisions

• Owns DFM/DFA review for battery pack assemblies; coordinates PPAP (Production Part Approval Process) readiness activities with supply chain and manufacturing engineering

Vehicle Systems & Integration

• Collaborates at vehicle architecture level with programme CPL (Chief Platform Lead), ID (Industrial Design), powertrain, and electrical teams to resolve packaging conflicts and meet system-level requirements

• Owns or contributes to major structural design (frame interfaces, swingarm, headlight structure, tail section) and dynamic structure design (impact load paths)

• Applies simulation tools - FEA (Altair HyperWorks or equivalent), CFD (Computational Fluid Dynamics), thermal analysis - to validate design decisions before physical builds; interprets and acts on analysis results independently

• Specifies and approves assembly and service procedures for assigned systems

Programme Execution & Cross-Functional Collaboration

• Provides input to programme schedules and cost targets; holds own due dates and understands downstream impact of schedule changes on manufacturing, purchasing, and regulatory milestones

• Generates and tracks ECOs (Engineering Change Orders) / CRs (Change Records) through the SAP ECTR release cycle; maintains BOM accuracy

• Prepares engineering documents to support regulatory type approval submissions, manufacturing engineering, and after-sales / service documentation

• Works effectively across Zero's geographically distributed team spanning Netherlands, Scotts Valley (CA), and OEM / contract development partner sites; communicates technical content clearly in English across time zones and cultural contexts

• Mentors MDE I-III engineers on design methods, process discipline, and engineering judgement; contributes to in-house mechanical design excellence

Supplier & Manufacturing Engagement

• Leads technical engagement with part manufacturers, tooling suppliers, and contract development partners on assigned systems

• Reviews and approves supplier DFM feedback, prototype builds, and PPAP submission packages

• Responds to and leads root-cause analysis for manufacturing non-conformances and field failures within assigned scope

Required Education / Experience

• Bachelor of Science (B.S.) or higher in Mechanical Engineering

• 7+ years of relevant mechanical design engineering experience in a product development environment; motorcycle, automotive, or e-mobility industry strongly preferred

• Advanced SolidWorks proficiency: complex part modelling, advanced surfacing, large assembly management, master modelling methodology, full drawing and GD&T annotation

• Comprehensive understanding of manufacturing processes: injection moulding, casting (die and sand), forging, CNC machining, weldments, sheet metal fabrication, surface treatments, and composites

• Demonstrated experience designing and releasing structural components (frames, brackets, load-bearing enclosures)

• Practical experience with IP-rated enclosure design and sealing system selection (FIPFG, compression gasket, adhesive)

• Proficiency with at least one FEA toolset (SolidWorks Simulation, Altair HyperWorks / Optistruct, ANSYS, or equivalent)

• Proven experience with BOM management, ECO/CR workflows, and document control in a PLM/PDM environment (SAP ECTR or equivalent)

• Demonstrated ability to lead groups through technical development and design review processes

Preferred Experience

• HV battery pack mechanical design - enclosure structures, module packaging, thermal management mechanical interfaces, and interconnect assembly design

• Familiarity with UN 38.3, IEC 62619, UN ECE R100 (electric vehicle safety), or AIS-156 as they relate to mechanical design obligations

• DFMEA facilitation experience; familiarity with APQP (Advanced Product Quality Planning) / PPAP discipline

• OEM programme experience - working with external design or manufacturing partners under a formal development and supply agreement

• European vehicle homologation experience (EU Regulation 168/2013 for L-category vehicles, UN ECE R10 EMC, UN ECE R48 lighting)

• Experience with motorcycle test riding in a product validation context

• Development and integration of innovative technical concepts, including patentable innovations

• Composite material design and specification

Requirements

Skills and Attributes

• Strong and autonomous sense of ownership - drives assigned work to completion and proactively resolves blockers

• Excellent written and verbal communication in English; Dutch language proficiency is a plus

• Positive and collaborative attitude in cross-functional settings; constructive under pressure

• Organised with superior attention to detail in design output, drawing quality, and release documentation

• Multi-tasking ability with effective scheduling, time management, and project prioritisation across parallel workstreams

• Hands-on mechanical aptitude - comfortable in a lab or workshop environment, confident with prototype assembly and diagnostic work

• Diligent, reliable, and tenacious in driving technical problems to root cause and resolution

Other Requirements

• Licensed motorcycle rider preferred

• Domestic and international travel required a few times per year (Scotts Valley HQ, manufacturing partners, OEM sites)

Why Zero Motorcycles

Zero Motorcycles, a leader and innovator in electric motorcycles and commercial powertrains, incorporates advanced technology, stunning design and commitment to environmental benefits. The EV space is growing dramatically, with Zero a leader in the two-wheel category and a rising star in powertrain applications to other OEMs electrifying sport and utility vehicles for powersport and industrial applications.

At Zero Motorcycles, you’ll join a passionate, fast-growing global team with a truly international spirit. While our roots in the United States, have branched-out to Europe and stablished in The Netherlands, our team now spans across more than 10 countries, representing over 15 nationalities-and counting! We thrive in a multicultural, multilingual environment where fresh ideas are welcomed, big dreams are encouraged, and success is celebrated together.

Our team is united by a shared mission and a love for what we do. Whether we're collaborating across time zones or catching up in the office, you'll find a group that’s driven, committed, and always ready to share a laugh.

We value connection beyond the work itself. From office lunches and Friday drinks to spontaneous barbecues when the sun’s out, and legendary Xmas parties and team-building days, we believe in having fun while we work hard.

Working with Zero Motorcycles, you’ll also have opportunities to represent us at events and trade shows-locally and internationally-if that’s something you enjoy. And as we continue to grow, so can you. We’re invested in your development and success, and we can’t wait to see where your journey with us will take you.

Additionally

• Competitive salary and benefits package.
• Opportunities for personal and professional growth.
• Inclusive and open-door culture with driven, fun colleagues.
• Work in a dynamic, innovative environment leading the EV revolution.