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Salary: USD 150,000 - 180,000 / annual
Arc is electrifying the marine industry by rethinking powertrains, software, and vessel designs from first principles. The company has proven core technology, is scaling production of its flagship consumer model, and is now extending its platform to commercial applications including tugs, ferries, and defense—with years of signed contracts and a pipeline spanning every vessel type.
As Senior Battery Mechanical Engineer, you will own the mechanical design of Arc's battery packs across product lines. This is a hands-on, full-ownership role reporting to the engineering leadership team.
Key responsibilities:
- Lead battery pack mechanical design from architecture through detailed structure, enclosure, busbar, and electronics packaging
- Perform structural analysis (FEA, hand calculations, numerical modeling) on enclosures, busbars, and internal components against vibration, shock, and slamming loads
- Size and design pack thermal management systems including cold plates, coolant routing, and heat rejection; validate models against test data
- Partner closely with electrical engineering on cell selection, busbar/interconnect design, HV isolation, creepage/clearance, and BMS/sensor integration
- Package battery packs into tight hull envelopes, balancing energy density, mass, safety, serviceability, and manufacturability
- Build and test prototypes hands-on, running thermal, structural, and abuse validation; drive design iterations from results
- Support sea trials to validate and certify systems in the field
- Interface with cell, module, and component suppliers; support production ramp
Required qualifications:
- 6+ years mechanical engineering experience, including 3+ years designing battery packs/modules from concept through production
- Strong structural and thermal engineering fundamentals with hands-on FEA, hand calculations, and numerical modeling experience
- Working knowledge of high-voltage battery systems: cell behavior, electrical isolation, thermal runaway, and how mechanical design drives safety
- Experience collaborating with electrical engineers on busbars, interconnects, and BMS/sensor integration
- Proficiency with major CAD (NX preferred) including large assemblies and detailed part design
- Experience creating and detailing engineering drawings with solid GD&T understanding
- Strong intuition for manufacturing methods—understanding how parts are made and their costs
- Practical experience designing, building, and troubleshooting hardware in production environments
- Clear written and verbal communication; strong time management
- Comfortable working at a fast but sustainable pace
- Willing to spend time on boats in the field collecting test data
- Takes full ownership, thinks from first principles, prioritizes technical problems efficiently
Bonus qualifications include cell-to-pack/module-to-pack design in automotive/aerospace/defense, familiarity with battery safety standards (UL 2580, UN 38.3, ISO 6469, ABYC E-13), fluid system design experience, sheet metal/CNC machining exposure, marine vessel experience with Coast Guard/ABS regulations, Matlab/Simulink modeling, and enthusiasm for boating.
