High Voltage Systems Engineer

Methode Electronics • Southfield, MI

15h

About The Position

Methode Electronics is seeking a High Voltage Systems Engineer to design, develop, and test high-voltage architectures, with a focus on next-generation 800V powertrain components, DC-DC converters, and planar magnetics. The role covers converter and magnetics design, power-board integration, thermal management, system simulation, hardware validation, functional safety, and troubleshooting. The engineer will also guide cross-functional technical teams and support complex engineering projects from concept through production.

The position involves working with high-voltage batteries, inverters, converters, cabling harnesses, power electronics, and specialized laboratory equipment. The work environment and physical demands are described as representative of essential job functions. Reasonable accommodations may be made for individuals with disabilities.

Requirements

• Bachelor’s or master’s degree in electrical engineering, power electronics, or a closely related technical field.
• At least 5 years of hands-on experience developing high-voltage systems above 60V, ideally in 400V to 800V+ architectures.
• Proven experience with switching topologies, gate-driver optimization, and magnetic component design.
• Deep knowledge of planar transformer construction, multilayer PCB winding layouts, and ferrite or nanocrystalline core selection.
• Hands-on experience implementing liquid cooling, forced-air systems, or phase-change cooling for high-power-density electronics.
• Familiarity with IPC-2221, IPC-9592, and automotive safety frameworks such as ISO 26262 or ASIL ratings.
• Proficiency with MATLAB/Simulink, PLECS, PSpice, or magnetic simulation tools such as ANSYS Maxwell.
• Experience using high-power laboratory tools, including high-voltage power supplies, electronic loads, oscilloscopes, and power analyzers.
• Strong communication skills and 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 using SiC/GaN wide-bandgap semiconductors.
• Design and optimize high-frequency planar transformers and inductors to maximize power density and minimize leakage inductance and interwinding capacitance.
• Connect, configure, and optimize high-power distribution boards, multilayer PCBs, and control circuits in vehicle powertrain or grid systems.
• Perform thermal analysis and design active cooling solutions, including liquid-glycol loops, phase-change materials, and thermal interface materials.
• Conduct system analysis, circuit-level simulations, stress modeling, and electromagnetic FEA for magnetic flux optimization.
• Lead 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 software, mechanical, and layout teams to execute engineering projects from concept to production.
• Implement functional-safety measures, including isolation monitoring, interlocks, and creepage/clearance requirements.
• Investigate and resolve power-flow instabilities, EMI/EMC issues, AC copper losses, and physical component failures identified during validation.

Benefits

• Medical, dental, vision, hearing, life, and disability insurance
• Educational assistance
• Paid time off
• Voluntary accident, hospital indemnity, and pet insurance plans
• Discount programs for certain technology, automotive, and home appliance products
• Employee Assistance Program (EAP)
• 401(k) plan with a company contribution

What This Job Offers

• Job Type: Full-time
• Career Level: Senior