Senior Mechanical Design Engineer (EV Battery Cooling & Thermal Systems)

Expleo is a trusted partner for end-to-end, integrated engineering, quality services and management consulting for digital transformation.  We help businesses harness unrelenting technological change to successfully deliver innovations that will help them gain a competitive advantage and improve the everyday lives of people around the globe.

We are seeking an experienced Senior Mechanical Design Engineer to support the development of advanced EV battery cooling and thermal management systems within a high-performance automotive environment.

The successful candidate will be responsible for the design and development of mechanical components and assemblies related to HV battery systems, including cooling circuits, expansion tanks, hoses, brackets, and associated interfaces. The role requires strong CAD capability, excellent engineering judgement, and experience working within automotive product development and release processes.

This position suits an engineer with a strong background in thermal systems, mechanical packaging, and automotive design engineering, ideally within EV, motorsport, or high-performance vehicle programmes.

• Design and develop mechanical components and assemblies for EV battery cooling and thermal systems
• Produce 3D CAD models and 2D manufacturing drawings using CATIA V5
• Apply GD&T principles in accordance with automotive standards
• Support requirements capture and engineering specification activities
• Perform engineering calculations including:
  • Conduct interface and packaging checks between new and existing vehicle systems
  • Prepare CAD models and geometry for CFD analysis
  • Support DFMEA activities and engineering risk assessments
  • Collaborate with suppliers to ensure Design for Manufacture (DFM) considerations are achieved
  • Support engineering release activities through PLM/PDM systems
  • Participate in design reviews and cross-functional engineering discussions
  • Ensure all work is completed in line with programme timing, quality, and engineering standards

• Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics, or a related engineering discipline.

• Strong mechanical design engineering capability within automotive environments
• Advanced experience using CATIA V5
• Excellent understanding of:
  • GD&T
  • Tolerance analysis
  • Mechanical packaging
  • DFM principles
• Experience designing cooling system components such as:
  • Expansion tanks
  • Coolant hoses
  • Pipework
  • Brackets and mountings
  • Clamping systems
• Ability to perform engineering calculations and design validation activities
• Familiarity with DFMEA processes and engineering release workflows
• Strong communication and cross-functional collaboration skills
• Ability to work independently within fast-paced engineering programmes

• Experience with HV battery pack integration and ESS systems
• Exposure to CFD workflows and thermal simulation support activities
• Knowledge of automotive PLM/PDM systems
• Understanding of APQP and automotive quality processes
• Familiarity with prototype build and validation activities
• Motorsport or high-performance automotive experience
• Understanding of lightweight structures and packaging optimisation
• Awareness of functional safety and EV system integration considerations

• Experience in automotive mechanical design engineering
• Experience working on EV or hybrid vehicle programmes
• Proven experience in HV battery thermal management or cooling system design
• Background within automotive OEM, motorsport, hypercar, or Tier 1 supplier environments
• Experience supporting full product development lifecycle from concept through release
• Experience interacting directly with suppliers and manufacturing teams

• Collaborative working environment – we stand shoulder to shoulder with our clients and our peers through good times and challenges 
• We empower all passionate technology loving professionals by allowing them to expand their skills and take part in inspiring projects 
• Expleo Academy - enables you to acquire and develop the right skills by delivering a suite of accredited training courses 
• Competitive company benefits
• Always working as one team, our people are not afraid to think big and challenge the status quo

• As a Disability Confident Committed Employer we have committed to:
• Ensure our recruitment process is inclusive and accessible
• Communicating and promoting vacancies
• Offering an interview to disabled people who meet the minimum criteria for the job
• Anticipating and providing reasonable adjustments as required
• Supporting any existing employee who acquires a disability or long term health condition, enabling them to stay in work at least one activity that will make a difference for disabled people

“We are an equal opportunities employer and welcome applications from all suitably qualified persons regardless of their race, sex, disability, religion/belief, sexual orientation or age”. 

We treat everyone fairly and equitably across the organisation, including providing any additional support and adjustments needed for everyone to thrive