Senior Product Development Engineer

Role details

Location

Ann Arbor, Michigan

Department

Product Engineering

Reports To

Director of Product Engineering

Employment Type

Full-Time

About EGI Battery

EGI Battery is a U.S.-based manufacturer of advanced lithium-ion batteries, focused on delivering NDAA-compliant energy solutions for critical applications. Headquartered in Ann Arbor, Michigan, EGI is building a secure, domestic supply chain to support the growing demand for high-performance batteries in drone, eVTOL, and energy storage markets.

Position Summary

EGI Battery is seeking a highly motivated and technically versatile Senior Product Development Engineer to support the development, industrialization, and launch of advanced lithium-ion battery products. This role serves as a key technical resource bridging Product Engineering, Design Release Engineering (DRE), and Process Engineering functions throughout the product lifecycle. The successful candidate will lead activities from early-stage research and development through prototype and pilot production while ensuring a successful transition into full-scale manufacturing.

The ideal candidate will possess a broad engineering background with experience in product design, manufacturing processes, technical documentation, and production launch activities. Working closely with R&D, Manufacturing, Quality, Supply Chain, Equipment Engineering, and external suppliers, this individual will help ensure products meet performance, quality, reliability, manufacturability, and cost objectives.

Essential Duties and Responsibilities

Product Development

• Support the development of lithium-ion battery products from concept through production launch.

• Collaborate with R&D teams to transform concepts into manufacturable products.

• Develop and maintain product specifications, engineering requirements, and technical documentation.

• Evaluate product performance, reliability, safety, and manufacturability during all phases of development.

• Support prototype builds, engineering trials, pilot production activities, and validation testing.

• Conduct technical analysis, root cause investigations, and corrective action implementation.

• Participate in product design reviews and cross-functional engineering reviews.

• Support customer, supplier, and internal technical discussions as required.

Design Release Engineering (DRE)

• Create, release, and maintain engineering drawings, specifications, bills of material (BOMs), and related documentation.

• Manage product configurations and engineering change control processes.

• Lead Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs).

• Ensure designs meet functional, manufacturing, quality, safety, and cost requirements.

• Coordinate design reviews and approval processes.

• Maintain document control and product traceability throughout the product lifecycle.

• Support implementation and maintenance of PLM and document management systems.

Process Engineering

• Develop and optimize manufacturing processes for battery products and assemblies.

• Support process development activities from laboratory and prototype environments through pilot manufacturing.

• Collaborate with equipment suppliers and manufacturing personnel to establish robust production processes.

• Develop process flow diagrams, manufacturing procedures, work instructions, control plans, and related documentation.

• Improve manufacturing safety, quality, yield, throughput, and cost performance.

• Lead troubleshooting and resolution of process-related manufacturing issues.

• Support process validation, capability studies, and continuous improvement initiatives.

• Assist in the specification, installation, qualification, and startup of manufacturing equipment.

New Product Introduction (NPI) and Production Launch

• Act as the primary technical liaison between R&D and Manufacturing.

• Assist with Design for Manufacturability (DFM) and Design for Assembly (DFA) reviews.

• Plan and coordinate prototype, engineering, pilot, and pre-production builds.

• Establish manufacturing readiness criteria and product launch plans.

• Support production ramp-up and transfer of products into manufacturing operations.

• Drive closure of launch-related technical issues.

• Ensure successful handoff of products and processes from development to production teams.

• Provide ongoing technical support during early production phases.

Required Qualifications

• Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, Chemical Engineering, Electrical Engineering, Materials Engineering, or a related engineering discipline.

• Minimum ten (10) years of experience in product engineering, manufacturing engineering, process engineering, battery manufacturing, automotive, electronics, or related industries.

• Experience developing and maintaining engineering drawings, specifications, and bills of material.

• Experience supporting new product development and manufacturing launch activities.

• Strong understanding of manufacturing processes and engineering change management.

• Demonstrated problem-solving and root cause analysis skills.

• Excellent written and verbal communication skills.

• Ability to effectively manage multiple projects and priorities in a fast-paced environment.

• Strong organizational and cross-functional collaboration skills.

Preferred Qualifications

• Experience with lithium-ion battery manufacturing.

• Knowledge of APQP, PPAP, FMEA, Control Plans, SPC, and MSA methodologies.

• Experience supporting prototype, pilot, and production manufacturing operations.

• Experience using CAD software such as SolidWorks, AutoCAD, CATIA, or similar platforms.

• Experience using PLM, ERP, and document control systems.

• Lean Manufacturing and/or Six Sigma certification a plus.

Knowledge, Skills, and Competencies

• Product Development

• Design Release Engineering

• Manufacturing Process Development

• Configuration Management

• Engineering Documentation and Change Control

• Design for Manufacturability (DFM)

• Design for Assembly (DFA)

• Root Cause Analysis

• Project Management

• Continuous Improvement

• New Product Introduction (NPI)

• Cross-Functional Leadership

• Technical Communication

• Battery Manufacturing Processes

Success in this role will be demonstrated through

• Successful development and launch of new battery products.

• Timely release and maintenance of engineering documentation and product definitions.

• Development of manufacturing processes capable of meeting safety, quality, throughput, and cost targets.

• Effective transfer of products from R&D through pilot production and into full-scale manufacturing.

• Improvements in product quality, manufacturing yield, and operational efficiency.

• Strong collaboration across engineering, manufacturing, quality, and supply chain functions.

Compensation

• The base salary range for this position will be determined based on the candidate’s experience, qualifications, skills, and other relevant factors.

• 100% 401(k) match up to 5% of base salary

• Medical, dental, and vision insurance through BCBS.

• This position is eligible for performance-based bonus and/or equity incentive plans in accordance with EGI Battery’s applicable programs.

Physical Demands

• Ability to work primarily from EGI’s Ann Arbor location and collaborate in office, laboratory, and manufacturing environments.

• Ability to travel domestically and internationally, as needed, for customer, supplier, equipment, facility, and program engagements.

• Ability to enter manufacturing and laboratory areas and comply with applicable safety and personal protective equipment requirements.

Work Authorization and Visa Sponsorship

• Applicants must be currently authorized to work in the United States.

• EGI Battery does not provide employment-based visa sponsorship for this position at this current time.