Mechanical Design Engineer

What to Expect

We build electric motorcycles. The engineering underneath them needs to be as deliberate, reliable, and honest as the ride itself — and this role is central to making that true. The Mechanical Design Engineer IV is an autonomous technical contributor and practitioner who drives component and system-level development without requiring design guidance or mentoring. Operating from Zero's Netherlands office, this engineer leads mechanical design work across powertrain enclosures, high-voltage (HV) battery pack mechanical systems, vehicle structures, and cross-functional system integration — collaborating directly with programme management, industrial design, supply chain, and OEM (Original Equipment Manufacturer) partners. At this level, the engineer is a practitioner others learn from: technically deep, methodical in decision-making, and highly effective at translating system requirements into production-ready hardware. 

Key Responsibilities

Technical Leadership & Design Ownership

• Leads design and development of complex motorcycle components and systems — including structural frames, battery enclosures, IP-rated sealing systems, and powertrain integration — through all programme phases (concept, F&D (Feasibility and Definition), D&R (Durability and Refinement), VAL (Validation), FPCS (First Production Conforming Sample))

• Owns the full technical definition of assigned line items: 3D CAD master models, GD&T drawings, DFM/DFA analysis, DFMEA facilitation, DVP&R (Design Verification Plan and Report) planning, and production release in SAP ECTR

• Drives design decisions independently using sound engineering judgement; communicates trade-offs and recommendations clearly to programme leads and management

• Leads design reviews at key programme gates; prepares and presents technically rigorous review packages, incorporating cross-functional feedback effectively

• Identifies and resolves critical path risks in design and integration; escalates unresolvable conflicts with full technical framing

Battery Pack & High-Voltage Mechanical Integration

• Leads mechanical design of HV battery pack structural and sealing systems, including enclosure design, thermal interface material (TIM) specification, module retention, and bus bar / interconnect packaging

• Defines mechanical interface requirements between the pack and vehicle structure, BMS (Battery Management System) electronics, cooling circuits, and regulatory compliance hardware

• Applies knowledge of UN 38.3 (transport testing), IEC 62619 (safety requirements for stationary and traction batteries), and relevant homologation standards (EU Type Approval, AIS-156 for India-market programmes where applicable) to design decisions

• Owns DFM/DFA review for battery pack assemblies; coordinates PPAP (Production Part Approval Process) readiness activities with supply chain and manufacturing engineering

Vehicle Systems & Integration 

• Collaborates at vehicle architecture level with programme CPL (Chief Platform Lead), ID (Industrial Design), powertrain, and electrical teams to resolve packaging conflicts and meet system-level requirements

• Owns or contributes to major structural design (frame interfaces, swingarm, headlight structure, tail section) and dynamic structure design (impact load paths)

• Applies simulation tools — FEA (Altair HyperWorks or equivalent), CFD (Computational Fluid Dynamics), thermal analysis — to validate design decisions before physical builds; interprets and acts on analysis results independently

• Specifies and approves assembly and service procedures for assigned systems

Programme Execution & Cross-Functional Collaboration

• Provides input to programme schedules and cost targets; holds own due dates and understands downstream impact of schedule changes on manufacturing, purchasing, and regulatory milestones

• Generates and tracks ECOs (Engineering Change Orders) / CRs (Change Records) through the SAP ECTR release cycle; maintains BOM accuracy

• Prepares engineering documents to support regulatory type approval submissions, manufacturing engineering, and after-sales / service documentation

• Works effectively across Zero's geographically distributed team spanning Netherlands, Scotts Valley (CA), and OEM / contract development partner sites; communicates technical content clearly in English across time zones and cultural contexts

• Mentors MDE I–III engineers on design methods, process discipline, and engineering judgement; contributes to in-house mechanical design excellence

Supplier & Manufacturing Engagement

• Leads technical engagement with part manufacturers, tooling suppliers, and contract development partners on assigned systems

• Reviews and approves supplier DFM feedback, prototype builds, and PPAP submission packages

• Responds to and leads root-cause analysis for manufacturing non-conformances and field failures within assigned scope

Required Education / Experience 

• Bachelor of Science (B.S.) or higher in Mechanical Engineering

• 7+ years of relevant mechanical design engineering experience in a product development environment; motorcycle, automotive, or e-mobility industry strongly preferred

• Advanced SolidWorks proficiency: complex part modelling, advanced surfacing, large assembly management, master modelling methodology, full drawing and GD&T annotation

• Comprehensive understanding of manufacturing processes: injection moulding, casting (die and sand), forging, CNC machining, weldments, sheet metal fabrication, surface treatments, and composites

• Demonstrated experience designing and releasing structural components (frames, brackets, load-bearing enclosures)

• Practical experience with IP-rated enclosure design and sealing system selection (FIPFG, compression gasket, adhesive)

• Proficiency with at least one FEA toolset (SolidWorks Simulation, Altair HyperWorks / Optistruct, ANSYS, or equivalent)

• Proven experience with BOM management, ECO/CR workflows, and document control in a PLM/PDM environment (SAP ECTR or equivalent)

• Demonstrated ability to lead groups through technical development and design review processes

Preferred Experience 

• HV battery pack mechanical design — enclosure structures, module packaging, thermal management mechanical interfaces, and interconnect assembly design

• Familiarity with UN 38.3, IEC 62619, UN ECE R100 (electric vehicle safety), or AIS-156 as they relate to mechanical design obligations

• DFMEA facilitation experience; familiarity with APQP (Advanced Product Quality Planning) / PPAP discipline

• OEM programme experience — working with external design or manufacturing partners under a formal development and supply agreement

• European vehicle homologation experience (EU Regulation 168/2013 for L-category vehicles, UN ECE R10 EMC, UN ECE R48 lighting)

• Experience with motorcycle test riding in a product validation context

• Development and integration of innovative technical concepts, including patentable innovations

• Composite material design and specification