Principal Battery/High Voltage/High Power Packaging Engineer

Posted Yesterday
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Austin, TX, USA
Hybrid
107K-183K Annually
Senior level
Aerospace • Hardware • Information Technology • Security • Software • Cybersecurity • Defense
Where purpose connects.
The Role
Design and develop complex battery, high-voltage, and high-power electronic packaging systems. Conduct thermal and structural analyses, resolve complex design challenges, and establish finalized designs. Collaborate with manufacturing, engineering teams, customers, and suppliers on materials, components, production, cost, schedules, and technical requirements. Support lightweight structures, thermal management, thermal runaway mitigation, and design-to-cost objectives while coordinating multiple priorities in a fast-paced environment.
Summary Generated by Built In
Job Description
We want your talent to support our development of power systems and high integrity electronic systems in our growing business. Controls and Avionics Solutions provides flight and mission-critical avionics and high-power drive systems to more than 170 commercial and military customers around the world.
CAS products include fly-by-wire flight controls, full authority digital engine controls (FADEC), power management systems, energy storage systems, cabin management systems, weapon controls, autonomous flight systems, and mission systems for the world's most prominent aircraft and commercial vehicle manufacturers. Our growing business is located in the Greater Binghamton area, home to sports teams, shopping centers, a growing downtown, the State University of New York at Binghamton, several large healthcare employers and some of New York's top-ranked school districts. The area enjoys a rich heritage with multiple diverse communities with local cuisine and festival celebrations. The Southern Tier area offers nearby access to hiking, skiing, lakes, waterparks, casinos, golfing, camping and vineyards. A 9/80 work schedule gives employees a great opportunity to experience all that the region has to offer and provides a balanced work and family lifestyle. Job responsibilities for the position include:
  • Assist in the design and development of complex products
  • Conduct analysis, summarize results and present findings
  • Interface with our manufacturing group, other engineering disciplines, customers and suppliers
  • Resolve complex design challenges and establish a finalized design approach

Required Education, Experience, & Skills
  • Bachelor's Degree in Mechanical Engineering or related discipline with 8+ years related experience
  • Keen interest in solving battery packaging challenges, including thermal runaway mitigation, efficient lightweight structures, thermal management, etc.
  • Knowledge of suppliers with innovative materials, components and techniques for efficient battery packaging
  • Knowledge in electronics packaging for high voltage/high power designs
  • Understanding of thermal and structural analysis and the resulting design impacts
  • Understanding of lightweight materials (e.g. composites) and manufacturing processes
  • Excellent communication skills to convey design concepts and support schedule, budget, and technical discussions with manufacturers, customers, engineers, and all levels of management
  • Ability to balance multiple tasks and priorities, and thrive in a fast paced, schedule driven environment
  • Ability to establish and maintain effective relationships with stakeholders across different parts of the business to achieve the optimal design and manufacture of the product
  • Sound interpersonal skills when coordinating with company personnel, customers, and suppliers
  • Exercise discretion and independent judgment in the performance of duties while complying with policies, procedures, appropriate principles and applicable state and federal laws.
  • Ability to take ownership of Design-To-Cost (DTC) objectives to meet overall price targets

Preferred Education, Experience, & Skills
  • Bachelor's Degree in Mechanical Engineering and 8+ years of related experience.
  • Experience with Battery Cell Packaging
  • Experience with High Voltage/High Power Electronics Packaging
  • Understanding of battery thermal runaway test standards
  • Knowledge of 3D CAD software tools.
  • Understanding of Thermal/Structural Analysis

Pay Information
Full-Time Salary Range: $107359 - $182510
Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.
Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.
About BAE Systems Electronic Systems
BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.
Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.
This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.

Skills Required

  • Bachelor’s degree in Mechanical Engineering or a related discipline
  • 8 or more years of related experience
  • Interest in solving battery packaging challenges, including thermal runaway mitigation, lightweight structures, and thermal management
  • Knowledge of suppliers, innovative materials, components, and techniques for efficient battery packaging
  • Knowledge of electronics packaging for high-voltage and high-power designs
  • Understanding of thermal and structural analysis and resulting design impacts
  • Understanding of lightweight materials, such as composites, and manufacturing processes
  • Excellent communication skills
  • Ability to balance multiple tasks and priorities in a fast-paced, schedule-driven environment
  • Ability to establish and maintain effective stakeholder relationships
  • Sound interpersonal skills when coordinating with personnel, customers, and suppliers
  • Ability to exercise discretion and independent judgment while complying with policies, procedures, and applicable laws
  • Ability to take ownership of Design-To-Cost objectives
  • Experience with battery cell packaging
  • Experience with high-voltage and high-power electronics packaging
  • Understanding of battery thermal runaway test standards
  • Knowledge of 3D CAD software tools
  • Understanding of thermal and structural analysis

What the Team is Saying

BAE Systems, Inc. Compensation & Benefits Highlights

  • Healthcare Strength Medical, dental, and vision coverage is presented as comprehensive, paired with an EAP, fertility and transgender care options, and HSA‑compatible plans that can include employer contributions with coverage starting on day one in some cases. These resources are reinforced by wellness tools and immediate eligibility noted on official benefits materials.
  • Retirement Support A 401(k) savings plan is broadly available, with employer matching and other contributions that vary by business unit, and some U.S. employee groups retain pension arrangements. Company‑paid basic life insurance equal to 2x base salary (up to $1M) further strengthens financial security.
  • Parental & Family Support Paid parental leave (e.g., 160 hours for full‑time employees) sits alongside adoption and surrogacy reimbursement and Bright Horizons backup child and elder care. These benefits help reduce care gaps and complement PTO and applicable state programs.

BAE Systems, Inc. Insights

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The Company
HQ: Falls Church, VA
40,000 Employees
Year Founded: 1999

What We Do

Improving the future and protecting lives is an ambitious mission, but it’s what we do. As a leading aerospace, defense, and security company, we work together to deliver a full range of products and services for air, land, space, and naval forces, as well as advanced electronics, security, information technology solutions and customer support services. How we work is rooted in purpose – a purpose to protect those who protect us, to unite our community of colleagues and customers, and to drive forward the growth and development of our exceptional team members. It's where purpose connects.

Why Work With Us

We believe your career should be filled with innovation and discovery. And that's exactly what you'll find at BAE Systems. As you work to develop the latest technology and defend national security, you will continually hone your skills and expand knowledge. On a sharp and collaborative team, you will be challenged – and supported – at every turn.

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BAE Systems, Inc. Teams

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Space & Mission Systems
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Electronic Systems
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Intelligence & Security
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Platforms & Services
About our Teams

BAE Systems, Inc. Offices

Hybrid Workspace

Employees engage in a combination of remote and on-site work.

As the work place continues to evolve, so do we. Remote and hybrid opportunities are available at BAE Systems depending on the nature of the role. Check your job requisition to learn more.

Typical time on-site: Not Specified
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HQBAE Systems, Inc. headquarters
Annapolis Junction, MD
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Austin, TX
Boulder, CO
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Space & Mission Systems headquarters
Burlington, MA
Cedar Rapids, IA
Dallas, TX
Endicott, NY
Fort Wayne, IN
Greenlawn, NY
Huntsville, AL
Jacksonville, FL
Los Angeles, CA
Maple Grove, MN
Intelligence & Security headquarters
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Electronic Systems headquarters
Redmond, WA
San Diego, CA
San Jose, CA
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Sterling Heights, MI
Washington, DC
Wayne, NJ
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