About the Opportunity
This fast-growing energy technology firm is currently scaling up its flagship battery energy storage solutions for commercial use. As they move from the development phase into high-volume production, they are looking for a skilled Wire Harness Design Engineer. The ideal candidate will possess advanced mechanical design skills and proficiency in Zuken E3 to help drive the next stage of product evolution. This position offers significant visibility, requiring close cooperation between mechanical, electrical, and manufacturing departments to ensure product reliability and successful deployment.
Position Overview
The Wire Harness Design Engineer will take full responsibility for the mechanical design, routing, and packaging of complex wiring systems within large-scale energy storage units. You will need hands-on expertise in harness architecture, connector selection, and mechanical packaging, specifically utilizing Zuken E3. Success in this role depends on your ability to work alongside cross-functional teams to create production-ready solutions that meet the demands of large-scale deployment.
Key ResponsibilitiesWire Harness Design & Development-
Utilize Zuken E3 and SOLIDWORKS to engineer and refine intricate wire harness systems.
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Produce comprehensive harness schematics, architecture layouts, and electrical interconnect documentation via Zuken E3.
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Develop detailed 2D and 3D harness models, installation blueprints, and manufacturing support files.
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Establish optimal harness routing paths, including branch points, breakout locations, and connector interfaces.
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Design mechanical retention components such as mounts, clips, brackets, and cable management systems to improve overall system stability.
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Refine harness configurations to enhance manufacturability, reliability, serviceability, and cost-efficiency.
Mechanical Integration & Packaging-
Route wiring harnesses throughout battery enclosures, sensor arrays, and auxiliary subsystems.
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Conduct packaging analyses to verify bend radius compliance, clearance requirements, and environmental protection.
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Assess routing paths to mitigate risks related to thermal exposure, vibration, abrasion, and assembly access.
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Partner with mechanical engineering staff to resolve integration hurdles and packaging conflicts.
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Assist in the integration of sensors and the mounting of electrical components within complex assemblies.
Connector Selection & Electrical Integration-
Choose appropriate terminals, connectors, cable protection, backshells, and sealing components.
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Engineer and integrate IP-rated connector systems capable of performing in challenging environments.
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Translate electrical schematics into actionable, manufacturable harness designs.
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Collaborate with electrical engineers to guarantee seamless system-level mechanical and electrical compatibility.
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Support the implementation of high-reliability electrical interfaces, shielding, and grounding requirements.
Documentation & Release-
Prepare engineering drawings, BOMs, wiring documentation, and full manufacturing packages.
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Maintain and update Zuken E3 harness documentation throughout the release cycle.
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Manage engineering change orders (ECOs) and configuration control processes.
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Create clear assembly instructions and manufacturing guides for production personnel.
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Verify documentation precision across all stages of development, validation, and final release.
Prototype & Production Support-
Provide technical support for pilot builds, prototype development, and production launches.
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Resolve harness-related challenges that arise during testing, integration, and assembly.
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Work with manufacturing teams to boost assembly quality and operational efficiency.
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Engage in root cause analysis and the execution of corrective measures.
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Contribute to production readiness and design validation efforts.
Required Qualifications-
Bachelor's degree in Mechanical Engineering or a closely related field.
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Minimum of 5 years of experience in wire harness design within a production setting.
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Proven proficiency in Zuken E3 for documentation, schematic development, and harness design.
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Extensive experience working with SOLIDWORKS.
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Demonstrated success in designing and releasing production-grade wire harness assemblies.
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Expertise in mechanical packaging, routing, and system integration.
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Experience in selecting connectors and designing effective retention and mounting hardware.
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Knowledge of sealed electrical interfaces, IP-rated connectors, and environmental protection standards.
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Ability to interpret and utilize wiring diagrams and electrical schematics.
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Experience in generating engineering drawings, BOMs, and manufacturing documentation.
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Solid understanding of Design for Assembly (DFA) and Design for Manufacturing (DFM) principles.
Preferred Background-
Battery Energy Storage Systems (BESS)
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Electric Vehicles (EV)
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Automotive
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Aerospace
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Industrial Equipment
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Robotics
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Power Electronics
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Renewable Energy Systems
Why Join-
Contribute to a scaling energy technology firm as they prepare a flagship product for wide-scale deployment.
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Engage in mission-critical hardware projects that define the future of grid-scale energy storage.
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Enjoy high levels of ownership and visibility within a diverse engineering team.
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Influence product design directly as it moves into the production phase.
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Take advantage of a long-term contract-to-hire opportunity.
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Benefit from initial onsite collaboration with increased flexibility after the onboarding and ramp-up period.
You should be proficient in:
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Electrical Schematics
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Thermodynamics
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PCB Assembly (Printed Circuit Board Assembly)
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Single and Three Phase Power
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120/208/240/480 Voltage Systems
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CAD Software
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Electrical Schematic Reading
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Engineering Degree
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E3
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mechanical engineer
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zuken
Machines & technologies you'll use:
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3D Modeling
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2D Drawings
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CAD Software (AutoCAD, Solidworks, Solid Edge, Catia)
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altium
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E3
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zuken
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harness
