Senior Manager, Linear Electric Machines Principal

Hyliion•Austin, TX

17h

About The Position

Hyliion is seeking a technical authority and people leader for its Linear Electric Machine (LEM), the permanent-magnet linear motor/generator at the heart of every KARNO generator. The LEM converts free-piston motion into electrical power and is also a building block for Hyliion’s multi-megawatt U.S. Navy and data center systems. The role is accountable for the machine’s electromagnetic and mechanical design, insulation and materials, testing and qualification, certification, and supplier and manufacturing readiness across current and future designs. The position leads the LEM engineering team in Cedar Park, Texas, scaling in-house production to volume at target cost, yield, and reliability, while partnering with Hyliion’s R&D team in Cincinnati, Ohio. It combines hands-on technical ownership with engineering team leadership, production scale-up, and technical representation to customers, partners, suppliers, and certification bodies. Hyliion expects team members to use its AI tools to accelerate work and problem-solving. This is a salaried, exempt-level role that typically works in a production, assembly, or engineering lab environment. Travel is estimated at approximately 20%, including regular trips to Hyliion’s Milford, Ohio facility and supplier sites. The role has or may have direct reports.

Requirements

Bachelor’s degree in Electrical, Mechanical, or Electromechanical Engineering, or a closely related field.
12 or more years designing, developing, and releasing electric motors or generators, including permanent-magnet machines taken from concept through production; 10 or more years with an MS or 8 or more years with a PhD.
At least 2 years leading engineering teams, including direct people management and hiring.
Demonstrated ownership of both electromagnetic and mechanical design of an electric-machine product, or deep expertise in one area with substantial hands-on depth in the other.
Track record launching or scaling electric-machine production, including winding and insulation systems, magnet assembly, end-of-line testing, and supplier development.
Expert knowledge of electric-machine theory, permanent-magnet machine design, magnetic materials, loss mechanisms, force ripple, and cogging.
Expertise in 2D/3D electromagnetic FEA and analytical sizing and optimization using MATLAB/Simulink or Python; proficiency with coupled thermal and structural analysis.
Strong mechanical design fundamentals, including 3D CAD, GD&T, tolerance stack-up analysis, and high-cycle component fatigue.
Working knowledge of power electronics and motor control, including field-oriented control, inverter-driven insulation stress, and machine-inverter co-design.
Hands-on experience with test rigs and fixtures, efficiency mapping, winding analyzers, data acquisition, and correlating test data to models.
Knowledge of manufacturing and quality methods including DFM/DFA, DFMEA/PFMEA, SPC, process capability, 8D/root-cause analysis, MRB, and supplier qualification.
Strong knowledge of and hands-on experience applying electric-machine standards and certification, including UL 1004, UL 1446, UL 2200, IEC 60034, NEMA MG 1, and IEEE standards.
Proven ability to lead and develop teams, coach senior engineers, and balance technical work with planning, prioritization, and resource management.
Clear communication with executives, customers, U.S. Navy reviewers, suppliers, and certification bodies; fluent use of AI tools for analysis, data review, documentation, and design exploration.
Ability to lift and/or move up to 20 kg (44 pounds).
Ability to work safely around strong permanent-magnet assemblies, high-voltage test equipment, and pressurized systems while following safety procedures and PPE requirements.
Ability to travel as needed, including by plane or automobile; estimated travel is approximately 20%.

Nice To Haves

MS or PhD focused on electric machines, electromagnetics, or power conversion.
Experience with linear machines such as linear alternators, free-piston generators, tubular permanent-magnet machines, or linear actuators.
Experience with high-voltage (800 V class), inverter-fed machines and insulation-system qualification and certification, such as UL 1004, UL 1446, or IEC 60034-18-41.
Experience with Siemens NX for 3D CAD.

Responsibilities

Serve as the accountable technical owner for the KARNO LEM throughout its lifecycle, from requirements and architecture through design, verification, release, production, and field performance.
Lead, hire, and develop electromagnetic, mechanical, and design engineers; set priorities, conduct technical reviews, and establish scalable standards, tools, and processes.
Own electromagnetic design and optimization of tubular permanent-magnet linear machines, using 2D/3D FEA and analytical models correlated with test data.
Own mechanical design of the translator, stator, and housing, including structural integrity, fatigue, air-gap eccentricity, radial side load, tolerances, GD&T, thermal management, and interfaces.
Own the stator insulation system and thermal design, including materials, processes, temperature sensing, partial-discharge and electric-field stress, thermal modeling, and thermal aging.
Partner with power electronics, controls, and systems teams on machine-drive co-design, including the 800 VDC architecture, inverter interface, position feedback, and transient load-step performance.
Define and execute the LEM technology roadmap for improved power density, efficiency, and cost, including concepts and scaling for multi-megawatt KARNO systems.
Lead design for manufacturing and assembly for the in-house LEM line; define quality characteristics and process windows, develop production documentation and tooling, and improve yield, cycle time, and cost.
Define LEM verification and production testing, including end-of-line tests, test-rig characterization, qualification, and life testing.
Own technical specifications and supplier qualification for critical materials and components; drive second-sourcing, incoming inspection, and cost reduction with Sourcing and Quality.
Lead DFMEA/PFMEA, reliability modeling, root-cause analysis, MRB/NCR disposition, and corrective action for build and field issues, incorporating telemetry and teardown findings into design improvements.
Maintain LEM certification and support KARNO-level certification and customer requirements; control drawing and engineering-change releases in the PLM system and assess certification impacts.
Represent the LEM in customer, U.S. Navy, partner, and supplier technical reviews; contribute to invention disclosures, patents, and technical proposals.
Perform additional duties and responsibilities as assigned, needed, or required for the business.