San Jose, California, United States
Built, managed, and led the pack product design team (6 direct reports) to develop the 9th and 10th generation battery pack assembly resulting in industry leading performance in volumetric and gravimetric packaging efficiency, mass, cost, and safety.
Facilitated pack team DRIs to design, release, and manufacture pack subsystems. This included 200+ total custom unique parts (each requiring 3D + 2D drawings and component manufacturing). Subsystems ranged from complex enclosure weldments, heat exchangers, cell stacks, cell monitoring boards, bus bars, trays, harnesses, power distribution assemblies, and battery management system PCBAs.
Worked with advanced manufacturing team and overseas vendors to develop novel components and final assembly manufacturing methods to complete the 9th generation pack builds.
Ensured design compliance with mechanical, electrical, thermal and environmental requirements via analysis, testing and model correlation.
Worked with broader team to optimize pack to product system integration and mechanical + electrical interfaces.