Sr Engineer, Mechanical Design – High Voltage EV Systems

Job Description

****Aptera Motors****

is dedicated to building a future where every journey is powered by the sun. We specialize in creating solar electric vehicles that revolutionize the way we travel, providing sustainable and efficient transportation solutions.

****Company Culture****
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is built on transparency, ethical treatment of one another, a bias for action, and leading by example.

****Sr Engineer, Mechanical Design -- High Voltage EV Systems****
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Carlsbad, California \| Engineering \| Full-time

****About the role****

We are seeking an experienced Mechanical Design Engineer with expertise in packaging high-voltage systems (400 V -- 800 V) for electric vehicles. This role focuses on designing compact, reliable, and safe enclosures and packaging for circuit board assemblies, busbars, harnesses, and high-voltage components. You'll work closely with electrical and systems engineers to ensure that mechanical packaging solutions meet demanding electrical, thermal, and safety requirements.

****What you'll do****

* Package ****high-voltage (400--800 V) automotive systems**** , including circuit board assemblies, busbars, harnesses, and power distribution units.

* Develop dense, compact layouts that optimize ****thermal performance, dielectric strength, clearances/creepage, and long-term reliability**** .

* Apply a working knowledge of ****dielectric properties of materials, thermal management, and material creep**** to ensure safe, durable designs.

* Collaborate with electrical engineers on ****component placement, routing, and packaging trade-offs**** .

* Incorporate ****EMI/EMC mitigation strategies**** into packaging solutions.

* Produce detailed ****3D CAD models and 2D drawings**** (CATIA preferred; willingness to learn required).

* Support harness routing and packaging using ****Arcadia**** (or learn quickly on the job).

* Participate in design reviews and work closely with suppliers to ensure manufacturable solutions.

* Hands on assembly of the designs for proving out design and creating work instructions.

****Qualifications****

* Proven track record in packaging ****400--800 V EV components**** (circuit board assemblies, busbars, harnesses, distribution units).

* Read and understand system schematics and wiring diagrams.

* Proficiency in ****3D CAD tools**** (CATIA preferred) with ability to deliver production-ready models and drawings.

* Familiarity with ****EMI/EMC design considerations**** in packaging.

* Bonus: Experience with ****Arcadia**** harness design tool.

****Team Structure****

* Individual contributor; collaborate with other teams and individuals, as necessary

****Required Experience****

* 5 years of experience in ****mechanical packaging of high-voltage systems**** for automotive or related industries

****Educational Requirements****

* ****Bachelor's degree (or higher) in Mechanical Engineering**** or related field

****Salary Benefits****

* Market competitive compensation package
* Stock option grants
* Fully funded benefits package for employee dependents
* Generous Flexible Time Away policy