Sr. Mechanical Design Engineer, Battery Electronics Packaging - Full-time / Part-time

Supernal is at the forefront of creating emerging mobility solutions that will foster the development of human-centered cities. We are designing a completely new electric vertical take-off and landing (eVTOL) aircraft tailored to the mobility needs of future cities. This allows passengers a seamless intermodal journey that safely transports them to their final destination. We fuse research in autonomy, robotics, aviation and services to define a new category of mobility for the world’s communities. We believe in creative thinking and collaboration to help build a better mobility experience for everyone, improving people’s ability to move – whether for work or play.

The Battery Pack Team is responsible for designing and prototyping high-voltage and high-power battery systems in electrified aircraft. The electronics packaging engineer for battery pack design is critical to the Energy Storage System (ESS) development process, including conceptual designs, components selection, prototype builds, and launch designs for volume manufacture.

The Sr. Mechanical Design Engineer, Battery Electronics Packaging, will design the mechanical aspects of electrical components and their packaging. The Electric Vertical Take-Off and Landing (EVTOL contains high-voltage printed circuit boards, flex circuits, cable harnesses, laminated bus bars, and sense circuits. The main responsibility of this role will be to plan and ensure the protection of these electronic components in the Supernal battery pack designs.

This position will be required to work on-site 5 days a week.

• Drive mechanical design of electrical components, interconnects, and electromechanical subsystem designs from conceptual and requirements development through production
• Select, prove, and implement the application of existing technologies to internal product development and develop new technologies to improve product metrics; for electromechanical components, this may include interconnects (solder bonds, welds, ribbon bonds, connectors, terminal lugs, spring fingers, etc.) and packaging interfaces (PCBA layup, flex layup, layout, vias, bolted mounts, heat stakes, over molding, snap fits, thermal interface materials, heat sink interfaces, harness insulation, shielding, strain relief, and cable management, etc)
• Provide technical expertise and mentorship to the team in electronics packaging and mechanical design of electronic components, such as wire harnesses, flexible printed circuit boards, connectors, laminated bus bars, and voltage, current, and temperature sense technologies
• Define specifications pertaining to electronic components (dimensional and dielectric, functional, performance, reliability, survivability, component manufacturing, and interface manufacturing
• Perform fundamental prototyping, testing, and analysis tasks and provide assistance for advanced analysis and validation testing
• Identify the root cause of issues in prototype, validation, and production stages and help in finding solutions for them
• Communicate work progress to department leadership through written and live updates, representing both individual and team efforts
• Collaborate with teams at Supernal sites and meet with suppliers for technology development, process validation, and issue resolution
• Build relationships with critical multi-functional teams in electrical design, testing, safety, abuse, manufacturing, systems, certification, and airframes
• Partner with PMO organization to implement build plan
• Up to 10% of domestic and international travel
• Other duties as assigned

• Bachelor’s degree in mechanical engineering or relevant engineering field required; Dual degrees in mechanical and electrical engineering preferred
• Minimum of five (5) years of experience in electromechanical component and subsystem design (an equivalent combination of education and experience may be considered)
• Experience designing electronic components: wire harnesses, connectors, flex printed circuit boards, laminated bus bars, voltage, current, and temperature sense circuits
• Experience designing for volume assembly, including manual and automated processes
• Ability to package electronics to achieve mass, thermal performance, sealing requirements, electrical grounding behavior, mechanical durability
• Knowledge of mechanical design fundamentals, electronic component materials, metallurgy, plating, interconnects, composites, harnesses, connectors, construction, thermal interface materials, dielectric materials, sealing methods
• Ability to translate product requirements into system and subsystem requirements
• Ability to translate subsystem requirements to part requirements and develop test plans to validate requirement achievement
• Proficiency in CATIA or similar 3D modeling system and at least one battery system modeling/simulation tool suite
• Excellent verbal and written communication skills
• Proactive delivery of communication and follow up
• Excellent organizational skills and attention to detail
• Must have the ability to independently prioritize and accomplish work within time constraints
• Proficiency with Excel VLOOKUP, pivot tables, MS Office Suite

• Experience in battery component design preferred
• Experience in aerospace preferred
• Experience in Altium or equivalent electronic design system preferred

Any offer of employment is conditioned upon the successful completion of a background check. We are an equal opportunity employer and value diversity at our company. We do not discriminate on the basis of race, religion, color, national origin, citizenship, sex, gender, gender expression, sexual orientation, age, marital status, veteran status, disability status or any other category or class protected under applicable federal, state or local law. Individuals with disabilities may request a reasonable accommodation to participate in the job application or interview process, to perform essential job functions, and to receive other benefits and privileges of employment. Please contact us to request accommodation at:

This position may include access to certain technology and/or software source code subject to U.S. export controls laws and regulations. If an export authorization from an applicable US regulatory agency is required in connection with your employment, your employment is contingent upon Supernal’s receipt of such regulatory authorization(s) and your continued compliance with all conditions and limitations pursuant to such authorization(s).