Director, Battery Pack Engineering Job at ALSO (Palo Alto)

Job Description

ALSO is seeking a technical leader who can grow high-performing engineering teams while delivering fully integrated, high-quality battery packs across mechanical, electrical, thermal, and safety domains.

Job Responsibility

Lead end-to-end battery pack product development, including detailed mechanical design, validation and testing, DFM/DFX, high-volume manufacturing ramp, certification, and continuous product and process improvements
Manage multiple battery technology and product development workstreams spanning early concept, detailed design, validation, launch, and sustaining engineering
Grow and lead several small engineering teams across mechanical design, test, modeling, and requirements engineering
provide coaching, prioritization, and technical guidance
Develop and maintain strong relationships with battery cell suppliers and drive cell selection and qualification for each new application
Expand cell- and pack-level performance and safety testing capabilities, including lab infrastructure, equipment, and test processes
Advance cell- and pack-level electrical, thermal, life, and health modeling capabilities to support design, controls, and safety analysis
Collaborate closely with Systems Engineering, Product Architecture, BMS hardware, and Controls Engineering to deliver integrated, high-performance battery systems

Requirements

BS or higher in engineering (mechanical or related) with strong grounding in mechanical design, structures, and heat transfer
Proven track record of industrializing multiple high-quality, high-volume battery packs or modules (0.5–8 kWh+ energy range)
Exceptional first-principles mechanical engineering skills with strong analytical, modeling, and design capabilities
Deep understanding of lithium-ion batteries, including operating principles, chemistry tradeoffs, failure modes, safety-by-design strategies, cell manufacturing, and the supplier landscape
Hands-on experience with safety-critical design, testing, and iteration, including strategies for controlled energy release during severe failure events
Strong experience working with contract manufacturers, including design release, documentation control, build readiness, on-site collaboration, and ramp-to-mass-production execution
Ability to develop and industrialize advanced manufacturing processes, such as wire bonding, laser welding, adhesive dispensing, and related joining/assembly flows
Strong understanding of battery safety and reliability qualification, including shock/vibration, environmental stress, abuse testing, and single-cell initiation methods
capable of building and interpreting test plans aligned with UL/IEC/UN regulations
Knowledge of physics-based modeling for battery cells and packs, plus familiarity with BMS algorithm design and performance methods
Understanding of BMS electrical architectures and hardware design, and how they integrate into battery packs

What we offer

Robust health coverage. Excellent health, dental and vision insurance covered up to 100% by ALSO with FSA & HSA options
One Medical membership and dedicated insurance advocates
Rich fertility and family building benefits with Progyny
Flexible time off
401(k) match

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Director, Battery Pack Engineering

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