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Lithos Energy

Mechanical Design Engineer Sep 2022 - Feb 2023 San Francisco Bay Area

Marine Battery R&D

Lithos Energy designs and manufactures high-performance lithium-ion battery packs for demanding applications. My role focused on the R&D of Low Voltage (LV) battery systems specifically for marine environments, where sealing, durability, and safety are critical.

Adhesive Validation & Testing

To ensure the long-term watertight integrity of marine battery packs, I led a comprehensive evaluation of sealing adhesives. This involved designing and fabricating custom test fixtures to isolate specific failure modes.

I conducted a rigorous battery of mechanical tests to validate adhesive performance under real-world stress conditions:

  • 3-Point Bending
  • Shear Strength
  • 90-Degree Peel
  • Drop & Impact

The data gathered from these experiments drove the final adhesive selection, optimizing the bond strength vs. flexibility required for thermal expansion and shock absorption.

Adhesive Testing Fixture
FEA Simulation of Battery Enclosure

Structural Optimization (FEA)

During initial destructive burst testing, the battery pack enclosures failed catastrophically, shattering into dangerous plastic shards. This uncontrolled failure mode posed a significant safety risk.

I implemented Finite Element Analysis (FEA) to model the internal pressure dynamics and structural response of the enclosure. The objective was not just to strengthen the pack, but to engineer a safe failure mode.

Solution: Using FEA, I designed an intentional "weak point" (pressure relief geometry) into the enclosure. This ensured that in an over-pressure event, the pack would vent predictably and safely rather than exploding.

Manufacturing & Rapid Turnaround

Bridging the gap between design and production, I authored detailed Manufacturing Instructions (MIs) and Standard Operating Procedures (SOPs) for assembly associates, ensuring consistent build quality.

I also acted as the first line of defense for production issues. When non-conforming parts arrived from vendors or assembly issues arose, I performed rapid design adjustments—modifying CAD geometry and tolerance schemes on the fly to keep the production line moving without compromising product performance.