High Voltage Systems Engineer

Methode Electronics•Southfield, MI

2d•Onsite

About The Position

We are looking for a skilled High Voltage Systems Engineer to join our dynamic engineering team. In this role, you will be at the forefront of designing, developing, and testing advanced, safe, and efficient high-voltage architectures—with a specific focus on next-generation 800V powertrain components, DC-DC converters, and advanced planar magnetics. If you have a passion for solving complex power electronics challenges, ensuring top-tier safety standards, and transforming cutting-edge electric vehicle (EV) concepts into reality, we want to hear from you.

Requirements

Bachelor’s or master’s degree in electrical engineering, Power Electronics, or a closely related technical field.
5 + years of hands-on experience developing high-voltage systems, specifically dealing with architectures exceeding 60V (ideally 400V to 800V+ systems).
Proven experience with switching topologies, gate driver optimization, and magnetic component design—including deep knowledge of planar transformer construction, multi-layer PCB winding layouts, and ferrite/nanocrystalline core selection.
Hands-on experience implementing liquid cooling, forced air systems, or phase-change cooling for high-power-density electronics.
Deep familiarity with IPC-2221, IPC-9592, and relevant automotive safety compliance frameworks (such as ISO 26262 or ASIL ratings).
Proficiency with simulation software (MATLAB/Simulink, PLECS, PSpice, or magnetic simulation tools like ANSYS Maxwell) and high-power lab tools (high-voltage power supplies, electronic loads, oscilloscopes, and power analyzers).
Strong communication skills with a track record of managing technical project timelines and guiding junior engineers.

Responsibilities

Architect, design, and optimize high-efficiency 800V DC-DC converters, onboard chargers, and traction inverters utilizing wide-bandgap semiconductors (SiC/GaN).
Design and optimize high-frequency planar transformers and inductors to maximize power density and minimize parasitic parameters (leakage inductance and interwinding capacitance).
Integrate Power Boards: Connect, configure, and optimize multiple high-power distribution boards, multi-layer PCBs, and control circuits within the overall vehicle powertrain or grid system.
Perform thermal analysis and design active cooling solutions—including liquid-glycol loops, phase-change materials, and advanced thermal interface materials—to manage high heat fluxes in compact planar magnetics and power modules.
Conduct detailed systems analysis, including circuit-level simulations, stress modeling, and electromagnetic Finite Element Analysis (FEA) for magnetic flux optimization.
Lead the physical testing of high-voltage batteries, inverters, converters, and cabling harnesses using specialized laboratory equipment under high-power conditions.
Guide, mentor, and align cross-functional technical teams (software, mechanical, layout) to execute complex engineering projects from concept to production.
Follow strict automotive and industrial safety standards, implementing isolation monitoring, interlocks, and creepage/clearance requirements to mitigate hazard risks.
Root-cause complex power flow instabilities, EMI/EMC issues (such as dV/dt noise coupling), AC copper losses (skin and proximity effects), or physical component breakdowns discovered during the validation phase.

Benefits

Medical
Dental
Vision
Hearing
Life and Disability insurance
Educational assistance
Paid time off
Accident insurance
Hospital Indemnity insurance
Pet Insurance coverage
Discount programs
Employee Assistance Program (EAP)
Participation in the Company's 401(k) plan, which includes a company contribution