High Voltage Systems Engineer

About Methode Electronics

We are a leading global provider of innovative automotive and industrial electronic products, including center stacks, switch banks, sensors, high-voltage busbars, Battery Disconnect Units (BDU), Integrated Circuit Boards (ICB), park brake actuators, ambient lights, and Center High-Mount Stop Lights (CHMSL). Our commitment to quality, innovation, and sustainability positions us at the forefront of the industry, delivering high-performance power distribution solutions to customers worldwide.

About Methode Electronics

We are a leading global provider of innovative automotive and industrial electronic products, including center stacks, switch banks, sensors, high-voltage busbars, Battery Disconnect Units (BDU), Integrated Circuit Boards (ICB), park brake actuators, ambient lights, and Center High-Mount Stop Lights (CHMSL). Our commitment to quality, innovation, and sustainability positions us at the forefront of the industry, delivering high-performance power distribution solutions to customers worldwide. 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.

Key Responsibilities

• 800V Converter Design: Architect, design, and optimize high-efficiency 800V DC-DC converters, onboard chargers, and traction inverters utilizing wide-bandgap semiconductors (SiC/GaN).
• Planar Magnetics Integration: 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.
• Manage Thermal Solutions: 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.
• System Simulation & Analysis: Conduct detailed systems analysis, including circuit-level simulations, stress modeling, and electromagnetic Finite Element Analysis (FEA) for magnetic flux optimization.
• Hardware Validation: Lead the physical testing of high-voltage batteries, inverters, converters, and cabling harnesses using specialized laboratory equipment under high-power conditions.
• Lead Teams: Guide, mentor, and align cross-functional technical teams (software, mechanical, layout) to execute complex engineering projects from concept to production.
• Ensure Functional Safety: Follow strict automotive and industrial safety standards, implementing isolation monitoring, interlocks, and creepage/clearance requirements to mitigate hazard risks.
• Solve Hardware Issues: 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.

Requirements

• Education: Bachelor’s or master’s degree in electrical engineering, Power Electronics, or a closely related technical field.
• Experience: 5 + years of hands‑on experience developing high‑voltage systems, specifically dealing with architectures exceeding 60V (ideally 400V to 800V+ systems).
• Power Electronics & Magnetics Expertise: 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.
• Thermal Management: Hands‑on experience implementing liquid cooling, forced air systems, or phase‑change cooling for high‑power‑density electronics.
• Hardware & Layout Standards: Deep familiarity with IPC‑2221, IPC‑9592, and relevant automotive safety compliance frameworks (such as ISO 26262 or ASIL ratings).
• Tools & Simulation: 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).
• Leadership: Strong communication skills with a track record of managing technical project timelines and guiding junior engineers.

Work Environment

The work environment charact