Battery Pack Engineer

AST SpaceMobile is building the first and only global cellular broadband network in space to operate directly with standard, unmodified mobile devices based on our extensive IP and patent portfolio and designed for both commercial and government applications. Our engineers and space scientists are on a mission to eliminate the connectivity gaps faced by today’s five billion mobile subscribers and finally bring broadband to the billions who remain unconnected.

Position Summary:
We are seeking a highly skilled Battery Pack Engineer to support the design, assembly, testing, and production optimization of advanced battery packs. The ideal candidate will have hands-on experience in battery pack assembly, be familiar with Arbin battery cyclers for performance testing, and have expertise in Amada and Hesse welding machines for precision welding of battery interconnections and busbars. This role involves working closely with production teams, quality engineers, and R&D to ensure high reliability and performance of battery systems.

Key Responsibilities:

• Design & Development:
• Support the development and optimization of battery pack designs, layouts, and electrical schematics.
• Define process parameters for welding, joining, and bonding operations for battery modules.
• Collaborate with R&D on cell selection, pack configuration, and system integration.
• Production Support:
• Oversee battery pack assembly processes, ensuring adherence to quality standards and production schedules.
• Operate and maintain Amada and Hesse welding machines for busbar and tab welding, ensuring proper weld quality and consistency.
• Define and maintain SOPs, process documentation, and assembly work instructions.
• Testing & Validation:
• Perform battery cell and pack testing using Arbin cyclers, including charge/discharge cycling, capacity verification, and performance characterization.
• Support failure analysis, root cause investigations, and corrective actions for battery performance issues.
• Assist in battery safety, environmental, and reliability testing as per industry standards.
• Quality & Safety:
• Ensure compliance with ISO, IATF, and other relevant quality management standards.
• Implement quality control measures for welding joints, electrical connections, and thermal management components.
• Enforce ESD and high-voltage safety protocols during production and testing activities.
• Continuous Improvement:
• Identify opportunities for process automation, efficiency improvement, and cost reduction.
• Provide feedback to equipment and process engineering teams for ongoing optimization.

Qualifications & Skills:

• Education: Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Materials Science, or a related field.
• Experience:
• 2+ years of hands-on experience in battery pack design, assembly, or testing.
• Direct experience with Arbin battery test equipment and Amada welding systems (laser or resistance welding).
• Strong understanding of lithium-ion battery technology, cell balancing, and BMS integration.
• Technical Skills:
• Proficiency in interpreting electrical schematics, CAD drawings, and mechanical assembly diagrams.
• Knowledge of welding parameters (current, pressure, pulse) and weld inspection criteria.
• Familiarity with data acquisition, test data analysis, and failure mode analysis (FMEA).
• Soft Skills:
• Strong problem-solving and troubleshooting skills.
• Ability to work collaboratively in a cross-functional production environment.
• Excellent documentation, communication, and reporting skills.