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)

Work arrangement
No