Freelance Product Designer

This role focuses on the redesign of a high-current brass battery terminal for advanced lithium battery packs in electric vehicle and energy storage applications. The primary objective is to reduce the terminal's weight while maintaining its electrical and mechanical performance. The successful candidate will leverage their expertise in connector design, 3D modeling, and FEA to deliver a robust, manufacturable solution that meets stringent industry standards. Responsibilities

• Redesign a 300A brass battery terminal to achieve a target weight reduction from 83.75g to approximately 57g without compromising performance
• Develop optimized 3D CAD models and detailed 2D drawings, including GD&T, material, and plating specifications
• Provide DFM recommendations for forging, stamping, or CNC production processes
• Conduct electrical and thermal FEA to assess current flow, temperature rise, and short-circuit forces
• Generate a derating curve and prototype validation plan covering thermal soak, contact-resistance, torque, and vibration testing
• Prepare a comprehensive design report summarizing test targets, validation results, and a comparison of weight and cost versus the current design

Skills And Requirements

• Proven experience in high-current connector design (≥200A), preferably for EV or energy storage applications
• Proficiency in 3D solid modeling using SolidWorks, Inventor, or Creo
• Advanced skills in FEA tools such as ANSYS, COMSOL, or SolidWorks Simulation
• Strong understanding of material selection and plating (brass/copper with nickel or tin finish)
• Familiarity with UL 1973 and IEC 62619 standards for battery safety and performance
• Ability to create detailed engineering drawings with GD&T and manufacturing specifications
• Experience with DFM for forging, stamping, and CNC processes
• Excellent analytical, problem-solving, and technical communication skills
• Ability to deliver thorough documentation, including validation plans and design reports

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