Hardware Engineer (Digital & Analog Circuit Design – AC Mains Systems)

Savant•Barnstable, MA

3d•$90,000 - $150,000

About The Position

We are seeking a Hardware Engineer with strong experience in digital and analog circuit design, including systems powered directly from AC mains. This role focuses on the design and development of mixed-signal hardware platforms that interface with high-voltage AC power, convert and regulate power safely, and integrate precision analog and digital control systems. The ideal candidate has hands-on experience designing offline power supplies, understanding regulatory requirements, and bringing products from concept through certification and production.

Requirements

Bachelor’s or Master’s degree in Electrical Engineering or related field.
5+ years of experience in digital and analog hardware design.
Hands-on experience designing circuits powered from AC mains.
Experience with offline AC-DC power supply design and switching regulators.
Strong understanding of:
High-voltage safety practices
Isolation techniques
Creepage/clearance requirements
EMI/EMC design principles
Experience with schematic capture and PCB design tools (e.g., Altium, OrCAD, Cadence, KiCad).
Proficiency in SPICE-based simulation tools.
Strong hands-on lab debugging skills.
Working knowledge of regulatory and safety standards for mains-powered equipment.

Nice To Haves

Experience with power factor correction (PFC) design.
Familiarity with surge immunity and ESD standards.
Experience participating in UL/IEC certification processes.
Experience with thermal design and power dissipation analysis.
Knowledge of embedded firmware interaction and system-level integration.
Experience supporting products from prototype through mass production.

Responsibilities

Design and develop digital and analog circuits for mixed-signal embedded systems.
Design circuits operating from AC mains (120/230VAC), including:
AC-DC power conversion (flyback, buck, PFC, isolated/non-isolated topologies)
Rectification, filtering, and surge protection
Inrush current limiting and EMI filtering
Isolation strategies (optocouplers, transformers, digital isolators)
Design and validate power supply subsystems (LDOs, DC-DC converters, battery backup systems as applicable).
Implement protection circuitry (overcurrent, overvoltage, thermal protection, short-circuit protection).
Ensure compliance with safety and regulatory standards (UL, IEC, CE, FCC, etc.).
Perform creepage and clearance analysis in PCB layout for high-voltage sections.
Develop and review PCB layouts with attention to:
High-voltage isolation barriers
EMI/EMC mitigation
Signal integrity and grounding strategies
Design analog front ends (AFEs) including amplifiers, filters, ADC/DAC interfaces, and sensor signal conditioning.
Integrate microcontrollers and digital interfaces (SPI, I2C, UART, USB, Ethernet as applicable).
Conduct circuit simulations (SPICE) and worst-case/tolerance analysis.
Develop and execute hardware validation and compliance test plans.
Troubleshoot and debug boards using oscilloscopes, differential probes, current probes, isolation transformers, and other lab instrumentation.
Support product certification testing and manufacturing ramp.
Create thorough design documentation and support DFM/DFT reviews.