Senior Manager, Mechanical Engineering

Senior Manager, Mechanical Engineering

Location: Gachibowli, Hyderabad, India

Full-Time/Onsite

Role Overview

We are seeking a senior mechanical engineering leader to own battery structural integrity across the full product lifecyclefrom early design and simulation through qualification testing and manufacturing ramp. This role leads a team of mechanical engineers at our Hyderabad R&D center and operates as a key technical partner to global R&D leadership. The ideal candidate combines deep FEA and structural analysis expertise with proven people management and cross-functional execution skills.

Responsibilities Leadership & Management

Lead and grow a mechanical engineering team; set technical direction, manage performance, define career development paths, and foster a culture of continuous learning.

Act as the primary liaison between mechanical engineering and senior R&D leadership, translating technical findings into business-relevant decisions.

Drive cross-functional collaboration with electrochemistry, manufacturing, and operations teams across clients global sites (Fremont, Penang, Nonsan, Hyderabad).

Make high-stakes technical decisions under uncertainty in a fast-paced R&D environment, balancing current product needs with next-generation development.

Travel up to 15% of the time to support production launch and ramp activities, including supplier visits and on-site support at global company facilities.

Technical Scope

Own battery structural integrity across the product lifecyclefrom design and simulation through qualification testing and manufacturing.

Direct development of micro- and macro-scale FEA models (ANSYS Mechanical, COMSOL, LS-Dyna) for battery structures, weld/adhesive joints, and dynamic fatigue (validated with nCode).

Guide integrated modeling of mechanical, thermal, and electrochemical interactions in battery manufacturing and operation.

Drive DOE-based design optimization (optiSLang or equivalent) and develop reduced-order models (ROM) to translate simulation insights into improved designs.

Define material characterization test plans and oversee fixture design to extract required material properties.

Lead root cause analysis on structural failures and define corrective actions.

Define optimal operating windows for process tools and equipment relevant to battery design and manufacturing.

Ensure battery integrity and safety compliance across qualification tests (drop, crush, etc.).

Improve DFM guidelines and raw material supply chain quality standards.

Required Skills & Qualifications

Experience: 15+ years of mechanical engineering experience, with at least 5 years leading engineering teams.

Education: M.S. or Ph.D. in Mechanical Engineering or a closely related field.

FEA expertise: Demonstrated expertise in structural FEA simulation (ANSYS Mechanical, COMSOL, or LS-Dyna) applied to structural integrity, fatigue, or failure analysis.

Materials: Experience with material characterizationdefining test requirements, interpreting results, and translating findings into design rules.

Project execution: Track record managing cross-functional projects from concept through production, including engagement with operations and executive leadership.

Judgment: Comfortable making high-stakes technical decisions in ambiguous, fast-moving R&D environments.

Communication: Able to clearly convey complex technical concepts to non-engineering stakeholders and senior leadership. Preferred Skills

Domain experience: Background in battery, consumer electronics, MEMS, or similarly miniaturized / high-precision manufacturing environments.

Battery mechanics: Familiarity with electrochemical-mechanical interactions in lithium-ion cells (e.g., electrode swelling, pressure generation, SEI mechanics).

Manufacturing: Knowledge of DFM principles and vendor/supply chain quality management.

Modeling: Experience with reduced-order modeling (ROM) or design optimization tools (optiSLang, Dakota, or similar).

Materials degradation: Corrosion and embrittlement assessment experience.

CAD: Proficiency in SolidWorks, CATIA, or equivalent.