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Zero Motorcycles

Mechanical Design Engineer 4

Design EngineeringUpdated on Nov 13
Full-timeAmsterdam, NetherlandsNo salary listed

About the Job

Requirements

  • A Bachelor of Science or higher in Mechanical Engineering is required.
  • At least 7 years of relevant mechanical design engineering experience in a product development environment is required.
  • Advanced SolidWorks proficiency is required, including complex part modelling, advanced surfacing, large assembly management, master modelling methodology, and full drawing and GD&T annotation.
  • Comprehensive understanding of manufacturing processes is required, including injection moulding, die and sand casting, forging, CNC machining, weldments, sheet metal fabrication, surface treatments, and composites.
  • Demonstrated experience designing and releasing structural components such as frames, brackets, and load-bearing enclosures is required.
  • Practical experience with IP-rated enclosure design and sealing system selection, including FIPFG, compression gasket, and adhesive, is required.
  • Proficiency with at least one FEA toolset is required, such as SolidWorks Simulation, Altair HyperWorks, Optistruct, or ANSYS.
  • Experience with BOM management, ECO/CR workflows, and document control in a PLM/PDM environment such as SAP ECTR is required.
  • The candidate must be able to lead groups through technical development and design review processes.
  • The engineer must communicate technical content clearly in English across time zones and cultural contexts.

Responsibilities

  • Lead design and development of complex motorcycle components and systems, including structural frames, battery enclosures, IP-rated sealing systems, and powertrain integration, through concept, feasibility and definition, durability and refinement, validation, and first production conforming sample phases.
  • Own the technical definition of assigned line items, including 3D CAD master models, GD&T drawings, DFM/DFA analysis, DFMEA facilitation, DVP&R planning, and production release in SAP ECTR.
  • Make independent design decisions, communicate trade-offs and recommendations to programme leads and management, and lead design reviews at programme gates, preparing and presenting review packages that incorporate cross-functional feedback.
  • Identify and resolve critical-path risks in design and integration, escalating unresolvable conflicts with technical context.
  • Lead mechanical design of HV battery pack structural and sealing systems, including enclosure design, thermal interface material specification, module retention, and bus bar/interconnect packaging.
  • Define mechanical interface requirements between the battery pack and vehicle structure, BMS electronics, cooling circuits, and regulatory compliance hardware.
  • Apply UN 38.3, IEC 62619, and applicable homologation standards, including EU Type Approval and AIS-156 for India-market programmes, to design decisions.
  • Own DFM/DFA review for battery pack assemblies and coordinate PPAP readiness activities with supply chain and manufacturing engineering.
  • Collaborate at vehicle architecture level with programme CPL, industrial design, powertrain, and electrical teams to resolve packaging conflicts and meet system-level requirements.
  • Own or contribute to major structural designs, including frame interfaces, swingarm, headlight structure, and tail section, and dynamic structure designs such as impact load paths.
  • Use FEA, CFD, and thermal analysis to validate design decisions before physical builds, and independently interpret and act on analysis results.
  • Specify and approve assembly and service procedures for assigned systems.
  • Provide input to programme schedules and cost targets, meet assigned due dates, and account for downstream effects of schedule changes on manufacturing, purchasing, and regulatory milestones.
  • Generate and track ECOs and CRs through the SAP ECTR release cycle and maintain BOM accuracy.
  • Prepare engineering documents for regulatory type approval submissions, manufacturing engineering, and after-sales/service documentation.
  • Work across the geographically distributed team in the Netherlands, Scotts Valley, California, and OEM/contract development partner sites.
  • Mentor MDE I–III engineers on design methods, process discipline, and engineering judgement, and contribute to in-house mechanical design excellence.
  • Lead technical engagement with part manufacturers, tooling suppliers, and contract development partners on assigned systems.
  • Review and approve supplier DFM feedback, prototype builds, and PPAP submission packages.
  • Respond to and lead root-cause analysis for manufacturing non-conformances and field failures within assigned scope.

Desired Qualifications

  • Motorcycle, automotive, or e-mobility industry experience is strongly preferred.
  • HV battery pack mechanical design experience, including enclosure structures, module packaging, thermal management mechanical interfaces, and interconnect assembly design.
  • Familiarity with UN 38.3, IEC 62619, UN ECE R100, or AIS-156 as they relate to mechanical design obligations.
  • DFMEA facilitation experience and familiarity with APQP/PPAP discipline.
  • OEM programme experience working with external design or manufacturing partners under a formal development and supply agreement.
  • European vehicle homologation experience, including EU Regulation 168/2013 for L-category vehicles, UN ECE R10 EMC, or UN ECE R48 lighting.
  • Experience with motorcycle test riding in a product validation context.
  • Experience developing and integrating innovative technical concepts, including patentable innovations.
  • Composite material design and specification experience.

About the Company

Zero Motorcycles

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