Redesign of 300A Brass Battery Terminal for EV & Energy Storage Applications

We are looking for an experienced mechanical/electrical connector design engineer to redesign a 300 Amp brass battery terminal used in a lithium battery pack enclosed in a plastic housing. The primary objective is to reduce the terminal weight from 83.75 g to approximately 57 g without compromising current-carrying capacity, temperature rise, or mechanical reliability. The deliverables include an optimized 3D CAD model and detailed 2D drawings with GD&T, material and plating specification (brass/copper with nickel or tin finish), and DFM recommendations for forging, stamping, or CNC production. You will be required to perform electrical and thermal FEA for current flow, temperature rise, and short-circuit forces, as well as provide a derating curve and a prototype validation plan covering thermal soak, contact-resistance, torque, and vibration. A final design report should summarize test targets and compare weight and cost versus the current design. Familiarity with UL 1973 and IEC 62619 standards and experience in high-current connector design (≥200A), solid modeling (SolidWorks, Inventor, or Creo), and FEA tools (ANSYS, COMSOL, or SolidWorks Simulation) are essential.

Budget range:
Simple project

Who are you, and what do you do?
Business Development Manager

In what capacity are you hiring?
For my company

Where are you in the hiring process?
I’m ready to make a paid hire

What type of work is this?
Single job

What experience level is needed?:
Mid-level (Industry Average)