RepRally · 1 day ago
Senior Mechanical Design Engineer
San Jose, CA
Full-time
Onsite
Senior Level
7+ years expRepRally is a stealth-mode battery startup focused on developing cutting-edge battery technology to promote clean energy. They are seeking a Senior Mechanical Design Engineer to lead the design and development of advanced structural enclosures for high-performance battery systems, ensuring robust and manufacturable designs that meet demanding performance and reliability requirements.
MarketplaceSoftware
Responsibilities
Own the design of structural components such as enclosures, trays, and covers that manage thermal, mechanical, and environmental loads
Lead architectural studies to explore tradeoffs across weight, stiffness, cost, manufacturability, and system-level impacts including energy performance, part interdependencies, and manufacturability
Drive optimization efforts with cross-functional teams, customers, and vendors to achieve robust, efficient, and manufacturable designs
Integrate design-for-manufacturing (DFM) and design-for-assembly (DFA) principles into all development stages
Ensure proper sealing, structural integrity, and corrosion resistance across all structural interfaces
Provide directional guidance through simulations to steer the design and architecture when dedicated CAE resources are limited
Develop comprehensive 2D drawing packages applying appropriate GD&T and conduct tolerance analyses to ensure assembly integrity and performance
Select materials and processes suitable for performance, manufacturability, and cost, balancing tradeoffs across multiple engineering and production considerations
Apply knowledge of manufacturing technologies such as sheet metal forming, extrusion, high-pressure die casting, welding, adhesive bonding, fasteners, and coating technologies
Work with internal and external partners to define tolerances, specifications, and production intent designs
Oversee suppliers from initial engagement through delivery, inspection, and validation of parts
Partner with CAE, test, and systems engineering teams to ensure designs meet performance and safety requirements
Collaborate with manufacturing, quality, and test teams to ensure design intent is realized in hardware
Communicate complex mechanical tradeoffs and decisions clearly to internal teams, partners, and customers
Support component and system-level validation, including vibration, structural, and environmental testing
Support in validation, durability, and abuse testing activities to ensure performance and reliability
Drive root-cause analysis and corrective actions for mechanical performance issues
Qualification
Required
B.S. or M.S. in Mechanical Engineering, Applied Mechanics, or a related field
7+ years of experience in mechanical or product design for structural systems (battery structures preferred; body structures also applicable)
Strong understanding of mechanical loads, materials behavior, and product lifecycle considerations
Experience with CAD tools (e.g., CATIA, NX, SolidWorks, or similar)
Familiarity with mechanical FEA tools (Abaqus, ANSYS, LS-DYNA, etc.) to provide guidance on simulation and validation
Proven experience working with suppliers from concept through delivery and testing
Knowledge of leak testing methods and structural validation processes is a plus
Familiarity with industry standards and regulations for structural or energy storage systems is a plus
Excellent communicator capable of presenting to multidisciplinary teams
Comfortable working in fast-paced, iterative environments with evolving product requirements
Benefits
100% covered medical, dental, and vision insurance for employees
401(k) with company match
Generous paid time off and holidays
Paid parental leave
And more
Company
RepRally
Developer of a wholesale platform to eliminate the barriers to distribution and broaden consumer access to high-quality products.
11-50 employees
H1B Sponsorship
RepRally has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (2)
2024 (1)
Funding
Current Stage
Early StageTotal Funding
unknownKey Investors
GreylockIndicator Ventures
2024-09-09Series A
2023-11-13Seed
2023-07-01Pre Seed
Leadership Team
Justin Donovan
CEO, Co-Founder
Daryn Lam
Co-Founder
Recent News
muventures
2023-08-30
Company data provided by crunchbase