Sr Engineer, Mechanical Design – High Voltage EV Systems

Aptera Motors

is dedicated to building a future where every journey is powered by the sun. We specialize in creating solar electric vehicles that revolutionize the way we travel, providing sustainable and efficient transportation solutions.

is built on transparency, ethical treatment of one another, a bias for action, and leading by example. 

Carlsbad, California | Engineering | Full-time 

About the role

We are seeking an experienced Mechanical Design Engineer with expertise in packaging high-voltage systems (400 V – 800 V) for electric vehicles. This role focuses on designing compact, reliable, and safe enclosures and packaging for circuit board assemblies, busbars, harnesses, and high-voltage components. You’ll work closely with electrical and systems engineers to ensure that mechanical packaging solutions meet demanding electrical, thermal, and safety requirements.  

What you'll do

• Package high-voltage (400–800 V) automotive systems, including circuit board assemblies, busbars, harnesses, and power distribution units. 

• Develop dense, compact layouts that optimize thermal performance, dielectric strength, clearances/creepage, and long-term reliability. 

• Apply a working knowledge of dielectric properties of materials, thermal management, and material creep to ensure safe, durable designs. 

• Collaborate with electrical engineers on component placement, routing, and packaging trade-offs. 

• Incorporate EMI/EMC mitigation strategies into packaging solutions. 

• Produce detailed 3D CAD models and 2D drawings (CATIA preferred; willingness to learn required). 

• Support harness routing and packaging using Arcadia (or learn quickly on the job). 

• Participate in design reviews and work closely with suppliers to ensure manufacturable solutions. 

• Hands on assembly of the designs for proving out design and creating work instructions. 

Qualifications

• Proven track record in packaging 400–800 V EV components (circuit board assemblies, busbars, harnesses, distribution units). 

• Read and understand system schematics and wiring diagrams. 

• Proficiency in 3D CAD tools (CATIA preferred) with ability to deliver production-ready models and drawings. 

• Familiarity with EMI/EMC design considerations in packaging. 

• Bonus: Experience with Arcadia harness design tool. 

Team Structure 

• Individual contributor; collaborate with other teams and individuals, as necessary

Required Experience

• 5+ years of experience in mechanical packaging of high-voltage systems for automotive or related industries

Educational Requirements

• Bachelor’s degree (or higher) in Mechanical Engineering or related field

Salary + Benefits 

• Market competitive compensation package
• Stock option grants 
• Fully funded benefits package for employee + dependents
• Generous Flexible Time Away policy