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Senior Design Engineer - Batteries

Milwaukee Tool · Brookfield, WI · Full time

Posted Apr 17, 2026 · We last checked this listing on Oct 6, 2026

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Likely interview questions for this role

Written from this job description, not a generic list. Each one notes what the interviewer is really checking.

About your past

Tell me about a platform-level design you led. How did you get other teams to adopt it?

What they are checking: Leading cross-project work through influence rather than authority.

Tell me about a time you found a design problem late in a project. What did you do?

What they are checking: Owning late problems honestly and finding a path that protects the product and schedule.

What would you do

You lead platform design while supporting many NPD projects. How do you handle a product team that wants a one-off change to the interface?

What they are checking: Protecting platform standards while still helping individual projects meet their goals.

How do you work with electrical engineers on thermal and current requirements for a mechanical interface?

What they are checking: Collaborating across disciplines so mechanical and electrical needs are both met.

About the work

The battery interface has to stay compatible across a whole platform of tools. How do you change it without breaking compatibility with packs already in the field?

What they are checking: Respect for backward compatibility, which is central to a battery platform users have already invested in.

Walk me through how you would design the terminal connection between a battery and a high-draw tool.

What they are checking: Understanding contact resistance, heat, wear and vibration at a high-current connection.

A terminal is running hot during a high-load test. How do you find out why?

What they are checking: Systematic thermal troubleshooting across contact force, materials, plating and geometry.

How would you design a latch so a pack stays put when a tool is dropped, but a user with gloves can still release it easily?

What they are checking: Balancing durability against user fit experience, which the posting names as a requirement.

What durability tests would you run on a battery interface, and how do you tie them to real jobsite use?

What they are checking: Linking insertion cycles, drop, vibration and contamination tests to actual user abuse.

How do you pick materials and plating for battery terminals?

What they are checking: Knowledge of conductivity, corrosion, fretting and cost tradeoffs in contact materials.

How would you use tolerance analysis to make sure every pack fits every tool on the platform?

What they are checking: Stack-up skill for parts made by many suppliers across many years.

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The full job description

As published by Milwaukee Tool.

Job Description: Senior Design Engineer – Battery Interface Team INNOVATE WITHOUT BOUNDARIES! At Milwaukee Tool we firmly believe that our People and our Culture are the secrets to our success – so we give you unlimited access to everything you need to create disruptive new technologies and solutions on our engineering teams. Our product Engineering Team is responsible for developing electromechanical solutions that ensure batteries and the connections to batteries meet thermal and durability performance requirements, maintain compatibility, and meet user fit experience expectations. In this role you will lead platform design projects and support many of the active NPD projects across the company. Every developmental phase of these critical components happens in-house under the watch of this team. We continue to invest in our engineering capabilities to keep Milwaukee Tool at the forefront of the industry. Behind our doors you’ll be empowered every day to own it, drive it, and do what it takes to design and develop the biggest breakthroughs in the industry. Meanwhile, you’ll have the support and resources of the fastest-growing brand in the construction industry to make it happen. Year after year, our team continues to make significant breakthroughs in the industry. We’re just getting started. To learn more about our story click HERE . Senior Design Engineer – Battery Interface Team This Senior Design Engineer’s primary role uses highly developed engineering expertise and project management/team abilities to contribute to the design and development of new and existing products in a fast-paced rapid growing environment. As a vital team member you will define, design, and optimize mechanical components including battery-to-tool connections (interfaces), terminals, and heatsinks while developing and maintaining company standards for compatibility across all battery platforms. Duties and Responsibilities • Lead technical resource and mechanical engineering leader on new product and platform design. • Consistently provide clear and concise communication to technical groups and varying levels of leadership. • Provide clear engineering information to Project Leaders and the Global Engineering teams facilitating trade off decisions cross functionally as well as marketing. • Ability to handle multiple mid to high complexity projects individually and as a team lead • Use engineering problem solving methods (FEA, DOE, Fishbone, FMEA, GD&T) to design, derive root cause, and solve ambiguous problems. • Serve as a technical resource on areas of expertise and provide consultation / mentorship to others. • Develop and maintain build test plans and methods between milestones to ensure project efficiency Job Requirements • Bachelor of Science Degree in Mechanical; Masters preferred • 5 years of design experience. • Proficiency in 3D CAD – NX, ProE, Solidworks, or similar as well as FEA. • Proficiency in GD&T (Geometric Dimensioning and Tolerancing) principles, ensuring precise and accurate mechanical designs. • Advanced presentation skills with a proven ability to navigate and resolve conflicts • Strong analytical skills, knowledge, problem solving, and experience in process development, design evaluation, and root cause analysis. • Experience creating and evaluating assembly stack ups to ensure fitment and intended functionality of design. • Experience with manufacturing processes – Stamping, plating, and injection molding • Ability to travel up to 10% (travel includes Domestic and International). • High interest in tools of the construction trades. Milwaukee Tool is an equal opportunity employer.

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