Staff Mechanical Design Engineer
About the role
About Brelle
Energy for what moves us.
The next generation of vehicles and aircraft won't be built with yesterday's manufacturing playbook.
Brelle is building a new approach to manufacturing for an increasingly electrified world, bringing together advanced engineering, software, testing, and automated production to develop and build high-performance energy and powertrain systems.
We're a California based, venture backed team working with some of the most demanding names in high performance mobility, including supercars and superbikes. Our work spans novel battery pack architecture, full-stack software, and automated manufacturing, with the goal of making machines lighter, safer, and more capable.
We're building something ambitious, and we're still early. That means real ownership, difficult technical problems, and the opportunity to see your work move from an idea to something real. We value people who think beyond their job description, challenge conventional approaches, and follow through on what they take on.
Build something exceptional. Own your work. See it move.
About the Role
As a Staff Mechanical Design Engineer, you'll own the design and development of battery module components from concept through production.
You'll work across cell retention, thermal management, safety systems, housing integration, and electromechanical interfaces, partnering closely with electrical, thermal, simulation, and software teams to optimize the complete battery pack and vehicle package.
This is a hands-on, high-ownership role where you'll be expected to make sound design decisions, solve complex problems, and drive your work forward with a high degree of autonomy.
What You'll Do
Own the design for a new module architecture— cell retention systems, thermal management strategies, safety systems, housing integration, and electromechanical interfaces
Work with cylinder and pouch cell formats in 400-1000V systems, optimizing weight, thermal performance, cost, and manufacturing feasibility
Collaborate cross-functionally with Brelle’s electrical, thermal, simulation, and software teams to optimize the complete battery pack package
Coordinate design work with pack team members to converge on feasibility for function, manufacturing, and reliability of modules in pack and vehicle
Develop a robust cell venting strategy and propagation protection while meeting manufacturing and cost targets
Identify and suggest missing requirements needed and drive completion of released requirements
What We're Looking For
Bachelor's or master's degree in mechanical engineering (or equivalent with demonstrated depth)
7-8+ years of mechanical design experience in automotive or motorcycle battery/powertrain development
Advanced CAD proficiency in CATIA V5/V6 (3DX), NX, or SolidWorks: complex assemblies, GD&T, production drawings
Robust understanding of lithium-ion cell as it relates to electromechanical and safety design constraints
Understanding of battery system architectures and HV safety requirements (400V+ systems)
Hands-on structural FEA experience: defining load cases, boundary conditions, interpreting results for design decisions
Experience with DFM for multiple processes: injection molding, stamping, casting, composites, machining, fabricating
Experience with DFMEA/DVP&R cycles and design release processes
Battery module or pack design experience—you've navigated cell-level constraints and thermal management complexity
Preferred Qualifications
Practical hands-on experience in professional or personal projects – interest in working directly on the parts/products in the lab
Thermal simulation experience (CFD or equivalent)—you understand heat transfer, material selection implications and can develop solutions to meet system-level requirements
Design experience integrating into vehicle platforms—you understand powertrain architecture and integration challenges
Experience working at or with automotive OEMs or Tier-1 Suppliers on electrified platforms.
Proven track record releasing components to production: you've worked in a high-pace environment, participated in design reviews, and understand how designs move from concept to production level parts
How We Work
At Brelle, we value people who take ownership, think beyond their immediate responsibilities, and care about the quality of what they build.
Our operating principles reflect how we work:
Big Picture: Understand the broader problem and how your work contributes to the outcome.
Team First: Work across disciplines, share context, and help the team succeed.
Lean In: Take initiative, identify what needs to happen, and step in to make progress.
Be Obsessed: Care deeply about the details, the engineering, and the quality of the result.
Follow Through: Take responsibility for outcomes and see the work through to completion.
We're looking for a leader who embodies these principles, builds trust through technical judgment and follow-through, and helps create an environment where strong engineers can do their best work.
Compensation & Benefits
Base Salary: $160,000 - $185,000
Meaningful equity participation through Brelle's Employee Incentive Plan.
Medical, dental, and vision (HMO/PPO)
401(k)
Flexible PTO
Team meals twice a week
Monthly team events
Brelle is an equal opportunity employer.