Senior Mechanical Design Engineer

Department: Physical Systems

Location: Los Alamitos

Employment Type: FullTime

About Brelle

“Energy for what moves us” defines our mission at Brelle. We develop frontier technology that pushes what’s possible in electrified performance. Based in California, Brelle engineers next-generation platforms for supercars and superbikes, working alongside leading high-performance brands across the US and Europe. Our innovations are built on a novel pack architecture, a full-stack software platform, and an advanced approach to automated manufacturing. Joining the team means working on making electric vehicles—on the road and on the racetrack—lighter, more engaging, safer, and capable of charging in minutes.

Our engineering teams are structured like small Skunkworks teams – nimble, cross-functional, and technical. Engineers are encouraged to explore new concepts and materials and expected to rapidly go from concept idea to prototype. Brelle engineers are given a high level of autonomy to develop and release their parts across programs.

Role Responsibilities

• 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

Technical Qualifications

• Bachelor's or master's degree in mechanical engineering (or equivalent with demonstrated depth)

• 5+ 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

You are...

• Fundamentally Curious – driven by a deep curiosity and motivated to break down complex problems to their first principles, allowing you to think outside the box and develop innovative design solutions

• Organized and Meticulous – possess an obsessive attention to detail, able to recognize efficiency in design, and always striving for the optimal solution

• Self-Motivated and Autonomous - highly self-motivated, capable of managing your own workload, taking ownership of projects, and driving tasks forward with minimal supervision

• Results-Oriented - driven by results and maintain a clear focus on the end goal while executing detailed tasks

• Collaborative Team Player - strong team player who actively supports teammates, communicates effectively, and contributes positively to the collective success of the teams

• Humble and Open-Minded – willing to accept feedback and learn, constantly seeking out new knowledge and integrating feedback to improve yourself and the products you own

Compensation & Benefits

Compensation

• Base Salary: $140,000 – $175,000. Compensation may vary based on experience, training, education, and scope of the role.

• Founding Engineer equity participation through Employee Incentive Plan

Benefits

• Medical (HMO, PPO), Dental, and Vision

• 401(k)

• Flexible PTO

Culture

• Team meals 2x per week

• Monthly team events