DESIGN ENGINEER

• Produce detailed 3D CAD models, 2D engineering assembly drawings, and component blueprints for lead-acid battery casings, top covers, terminal structures, and pole sealing assemblies using SolidWorks, UG (Unigraphics), or Pro/ENGINEER.
• Perform tolerance stack-up analysis and adjust design specifications to match local Malaysian plastic injection molding capabilities, controlling shrinkage rates, draft angles, and wall thickness uniformity.
• Plan, track, and oversee mold trial runs (T1/T2/T3) for plastic injection tooling and terminal lead-alloy die-casting molds, evaluating sample dimensions, structural integrity, and assembly fit.
• Execute complete physical and dimensional inspections on trial samples, log defect root causes ( sink marks, warping, mold flash, or material porosity), and generate formal Mold Acceptance Reports.
• Lead Design Failure Mode and Effects Analysis (DFMEA) for new battery development, implementing preventative design actions to resolve critical defect risks such as terminal acid creep, container bulging, thermal deformation, and cover seam leaks.
• Establish technical testing protocols and acceptance thresholds, including airtightness pressure testing (20–30 kPa), internal hydraulic burst pressure, electrical capacity, and high-temperature/humidity environmental aging tests for tropical climates.
• Compile and maintain technical documentation, including product specification sheets, engineering change orders (ECOs), multi-level Bill of Materials (BOMs), explosion diagrams, and Key Characteristic (KC) identification lists.
• Collaborate with manufacturing and process engineers to validate design for manufacturability (DFM) and local assembly feasibility, specifically for terminal epoxy resin potting, heat-sealing, and laser welding lines.
• Assess local raw material feasibility (PP/ABS resins, lead alloys, sealing adhesives), evaluate component standardization across product lines, and account for import tariffs to optimize unit cost structures.
• Coordinate technical transfers and maintain alignment between China HQ R&D teams, local Malaysian plant production operations, and external local tooling vendors throughout the product lifecycle.