Empowering New Engineers in Battery Pack Design

Work Experience

Senior Project Engineer – Battery Pack Lead

FEV North America, Inc. · Full-time · Jan 2022 – Present · Auburn Hills, Michigan

Leading mechanical design for EV battery packs from concept to production. Managing cross-functional teams to deliver solutions meeting cost, quality and mass targets. Specializing in thermal management systems and battery safety design.

Battery Pack Design Lead:
● Directed a team of 5+ engineers/designers in end-to-end HV battery pack development for a 120kWh platform,
delivering 100% of stakeholder deliverables on schedule for successful launch.
● Defined High Voltage Battery Pack system requirements, interactions, and mechanical/thermal/electrical interfaces.

HV & BDU Design & Thermal Safety Expertise:
● Owned design/release of Battery Disconnect Units (BDUs) integrating contactors, fuses, current sensors, and HVIL
circuits for 400V systems.
● Mitigated thermal propagation risk by designing integrated mica thermal barriers in the high-voltage system
● Executed GD&T schemes, tolerance stack analysis, fastener analysis, and creepage-clearance validation (per ISO
60664).

Design & Release:
● Drove DFM/DFA initiatives with Tier 1 suppliers and plant teams, optimizing battery pack and high voltage assemblies
for large-scale production, cost reduction, and manufacturability.
● Managed full product lifecycle (concept to PPAP) for complex BDU subsystems, releasing 100+ drawings to supplier

Mechanical Engineer

Hybrid Design Services Inc · Full-time · Sep 2019 – Jan 2022 · Troy, Michigan

Designed components for battery packs in hybrid/electric vehicles and grid storage. Performed FEA/CFD analysis and managed supplier collaborations. Supervised CAD teams and optimized designs for manufacturing.

Battery Pack HV System Design
● Led design of critical HV components, including high-current bus bars, fused connections, HV/LV harnesses, UL9 V-0 injection molded plastics, structural enclosures, and coldplates for automotive/grid-storage battery packs.
● Spearheaded complete module design for grid-scale energy storage systems from initial concept to release.

Battery Cooling System Design & Simulation
● Designed, optimized, and simulated liquid-air cooling plates/strategy for a 2MW grid-scale battery system, ensuring
thermal performance targets.
● Developed & simulated prototype thermal management systems for an OEM pickup truck, evaluating liquid cooling,
phase change materials (PCM), and alternative thermal solutions.
● Optimized forced-air cooling systems via simulation for drone battery packs, enhancing thermal management
efficiency.

Research Assistant

University of Michigan · Jul 2019 – Sep 2019 · Ann Arbor

Conducted Life Cycle Assessments for waste management systems using Umberto. Developed comparative models for traditional vs innovative treatment methods.

Graduate Student Instructor

University of Michigan · Sep 2018 – Dec 2018 · Ann Arbor

Taught ME 560: Modeling of Dynamic Systems to 40+ students. Facilitated course operations under Prof. Jeffrey Stein.

Robotics Applications Intern

Dassault Systèmes · May 2018 – Aug 2018 · Auburn Hills

Built 25+ robotic models in Delmia D5/3DExperience. Developed documentation and contributed to robot programming tools using VB.NET.