HV Battery Design & Release Engineer – Busbar-to-Cell Welding, Array & Thermal

Ford Motor Company

. Design, validate, and release high-voltage battery array modules .

Posted 10/20/2026full-timeDearborn • Michigan • United StatesJuniorMid-Level💰 $68,300 - $192,900 per yearWebsite

Core Competencies

Role fit

Core Competencies

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Demonstrates expertise in high-voltage battery array design and release, with a strong focus on welding engineering specifications and process optimization. Proficient in cross-functional collaboration and effective communication with stakeholders to drive project success.

Highest-signal resume keywords

High-Voltage Battery EngineeringWelding Process EngineeringDesign And Release ActivitiesDVP&R And Test Plans DevelopmentSupplier Management

ATS Keywords

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Applicant Tracking System Keywords

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Hard Skills

Electrical EngineeringMechanical EngineeringWelding EngineeringGD&T StandardsFailure Mode Avoidance (FMA)DFMEAPFMEACapability StudiesLaser Welding ProcessesWeld Quality Analysis

Soft Skills

Strong Communication SkillsTeam LeadershipOrganizational SkillsDetail-OrientedProactive

Tools & Technologies

CAD SoftwareCAE ToolsQuality Document Development ToolsManufacturing Process ToolsElectrical Systems Knowledge

Industry Keywords

Electrified PowertrainHV Battery Array DesignPPAPManufacturing LaunchPlant Trials

Tech Stack

Tools & technologies

Assembly

About the role

Key responsibilities & impact

Design, validate, and release high-voltage battery array modules
Work with CAD designers, CAE engineers, HV battery package engineers, suppliers, welding process engineers, and HV battery component engineers
Develop and ensure compatibility of electrical, mechanical, and thermal module interfaces within the HV Battery System
Design or evaluate supplier designs for module components using engineering and manufacturing-process knowledge
Work with functions and global teams to meet package, performance, and attribute requirements
Complete Design and Release activities, including WERS component release, validation, issue management, quality-document development, and delivery
Interface with HV Battery unit, manufacturing, cell, testing, Supplier Technical Assistance, and Purchasing teams
Identify process and design improvements for efficiency and cost savings
Report design, testing, timing, and quality issues to leadership and lead technical resolution
Own and develop the busbar-to-cell laser-welding engineering specification through BME review and release
Define welded-joint requirements for structural integrity, electrical conductivity, and thermal management
Develop and execute DV and PV test plans supporting PPAP of the process assembly line
Develop capability studies with BME; minimize scrap, improve First Time Through, and improve cycle time
Support early plant trials and pre-production builds, including onsite plant work
Review weld-quality data and cross-section analyses to refine process parameters and requirements

Requirements

What you’ll need

B.S. in Engineering (Mechanical, Electrical, Materials, or Welding Engineering) with 5+ years of relevant experience, OR M.S. in Engineering (Mechanical, Electrical, Materials, or Welding Engineering) with 2+ years of relevant experience
Relevant experience in electrified powertrain or HV battery engineering systems, HV battery array design and release, or welding/joining process engineering
Experience in Design and Release roles, supplier management, and multi-discipline engineering in electrification
Experience writing requirements and engineering specifications, and evaluating supplier designs against them
Experience developing and evaluating DVP&R, DV and PV test plans
Experience with the Failure Mode Avoidance (FMA) process and quality documents including DFMEA, PFMEA, and control plans
Knowledge of GD&T standards, 2D prints, and tolerance stack-up analysis methods
Strong presentation and communication skills to report to Managers, Chief Engineers, Directors, and New Model Launch Leaders
Ability to work effectively across vehicle-program functions and interact with internal and external stakeholders, including negotiating tradeoffs
Proactive, self-motivated, and detail-oriented
Strong teamwork, organizational, oral, and written communication skills
Willingness to travel as needed for plant support and design reviews
Experience with laser welding processes and parameters, and knowledge of welded electrical-joint requirements
Experience with weld quality analysis, such as cross-section review
Experience with capability studies, scrap reduction, FTT, and cycle-time optimization
Experience with PPAP and manufacturing launch or plant trials
Knowledge of electronics manufacturing, soldering, wiring, SMT, connectors, and electrical systems
Knowledge of stampings, castings, and injection-molded plastics
Team leadership experience
Must be legally authorized to work in the United States
Visa sponsorship is not available

Benefits

Comp & perks

Immediate medical, dental, vision and prescription drug coverage
Flexible family care days
Paid parental leave
New parent ramp-up programs
Subsidized back-up child care
Family building benefits including adoption and surrogacy expense reimbursement and fertility treatments
Vehicle discount program for employees and family members
Management leases
Tuition assistance
Established and active employee resource groups
Paid time off for individual and team community service
Generous schedule of paid holidays, including the week between Christmas and New Year’s Day
Paid time off
Option to purchase additional vacation time