Drone Battery Pack Design Engineer II, Prime Air

We are seeking a Drone Battery Pack Design Engineer II to join our Electric Propulsion Subsystem (EPS) team. In this role, you will be a significant and autonomous contributor, solving difficult hardware engineering problems related to battery systems. You will design, develop, and validate battery packs from concept through production, working on high-voltage battery systems that push the boundaries of performance, reliability, efficiency, and safety.

This position requires an engineer who demonstrates strong technical depth in battery pack design while also exhibiting the system-level thinking and influence characteristic of our most impactful contributors.

Key job responsibilities

Design & Development

Design the mechanical architecture for high-voltage Li-Ion battery packs, including cell arrangement, modules, enclosures, structural supports, and interconnections, balancing energy density, safety, and manufacturability

Create 3D models and manufacturing drawings in CATIA with GD&T

Design and integrate thermal management systems and sealed, IP-rated enclosures

Analysis & Validation

Perform FEA (structural, vibration, thermal) and tolerance stack-up analysis

Plan and execute prototype builds, validation testing, and root-cause failure analysis

Safety & Compliance

Design to high-voltage safety requirements, including creepage/clearance, isolation, and HVIL

Incorporate thermal runaway mitigation and comply with standards (UN 38.3, UL 2580, IEC 62133)

Develop verification test plans against DO-160 and DO-274, and support DFMEA

Collaboration & Process

Partner with electrical, BMS, systems, safety, manufacturing, and supply chain teams on interfaces, DFM/DFA, tooling, and sourcing

Present at design reviews and maintain documentation and change control in PLM

Support project planning with estimates, timelines, and risk assessments

Improve cost, weight, safety, and manufacturability Basic qualifications

• Bachelor's degree in mechanical engineering or equivalent
• 4+ years of working in mechanical engineering or equivalent experience
• Demonstrated experience taking a mechanical design from concept through prototype to production.
• Battery pack mechanical design: cell-to-pack architecture, module design, cell holders, busbar integration, enclosures, and structural support for prismatic, cylindrical, or pouch cells.

Preferred qualifications

• CAD proficiency (SolidWorks, Creo, CATIA, or NX) for 3D modeling, GD&T, detailed drawings, and tolerance stack-up analysis
• Thermal management design, including cooling systems (liquid cold plates, air, phase-change, or immersion), thermal interface materials, fast-charge and high-C-rate applications, and thermal runaway mitigation
• FEA for stress, vibration, shock, and drop, plus scripting and simulation tools (MATLAB, Python) for design automation or thermal modeling
• Enclosure and high-voltage design: IP-rated sealing, creepage and clearance, isolation coordination, and interfaces with the BMS, contactors, fuses, HVIL, and service disconnects
• Design for manufacturing and assembly, including pack joining methods (laser, ultrasonic, or resistance welding; adhesives; fastening) and supplier work on tooling, molding, sheet metal, die casting, or extrusions
• Prototyping, bring-up, and validation testing (environmental chambers, vibration tables, HALT/HASS), plus DFMEA and design-for-safety methodology
• Experience with automotive, aerospace, marine, or grid-storage battery systems, including how cell chemistry drives mechanical and thermal requirements

Amazon is an equal opportunity employer and does not discriminate on the basis of protected veteran status, disability, or other legally protected status.

Our inclusive culture empowers Amazonians to deliver the best results for our customers. If you have a disability and need a workplace accommodation or adjustment during the application and hiring process, including support for the interview or onboarding process, please visit https://amazon.jobs/content/en/how-we-hire/accommodations for more information. If the country/region you’re applying in isn’t listed, please contact your Recruiting Partner.

The base salary range for this position is listed below. Your Amazon package will include sign-on payments and restricted stock units (RSUs). Final compensation will be determined based on factors including experience, qualifications, and location. Amazon also offers comprehensive benefits including health insurance (medical, dental, vision, prescription, Basic Life & AD&D insurance and option for Supplemental life plans, EAP, Mental Health Support, Medical Advice Line, Flexible Spending Accounts, Adoption and Surrogacy Reimbursement coverage), 401(k) matching, paid time off, and parental leave. Learn more about our benefits at https://amazon.jobs/en/benefits .

USA, WA, Seattle - 136,000.00 - 184,000.00 USD annually