Test Engineer – Mechanical

Job Title: Mechanical Test Engineer

Location: Palo Alto, CA

Type: Full-Time

Role Overview

We are seeking hands-on, mechanically oriented Test Engineers who thrive in a fast-paced test lab environment. The ideal candidate will balance both technical depth and operational execution, working closely with design, reliability, and manufacturing teams. This role combines mechanical design, test setup development, instrumentation, and data-driven validation to ensure product reliability and safety.

You will be responsible for designing, building, and validating test fixtures and equipment used to evaluate next-generation power, control, and mechanical systems.

Key Responsibilities

1. Design & Build of Test Fixtures

• Architect and assemble test frames (80/20, steel, aluminum, composites) to house power systems, control electronics, and DUTs.
• Design and build custom control boxes (microcontroller/relay/switching boards) to automate and monitor test logic.
• Create harnessing for control and data lines, ensuring safe and efficient cable management.
• Integrate components such as power supplies, pumps, sensors, and DAQs.
• Develop control scripts (Python preferred) for automation, data logging, and fault handling.
• Decompose tasks into JIRA tickets, supervise technicians, and ensure quality execution.

2. Mechanical Systems & Thermal / Structural Design

• Select and integrate pumps, actuators, motors, and heat exchangers based on test requirements.
• Design fixtures, mounts, and supports considering stiffness, tolerances, and thermal expansion.
• Apply GD&T principles to ensure precision alignment and manufacturability.
• Manage fabrication via internal shops or external vendors.
• Understand and simulate mechanical stresses, vibration, and thermal behavior under test conditions.

3. Electrical, Instrumentation & Signal Integrity

• Interpret datasheets and design circuits for HV/LV components (contactors, shunts, relays).
• Size and design wiring harnesses with appropriate shielding, grounding, and noise mitigation.
• Integrate instrumentation (NI DAQ, thermocouples, RTDs, current/voltage sensors).
• Implement HV safety features: interlocks, insulation monitoring, watchdogs, and emergency shutdowns.
• Maintain signal quality and synchronization across measurement systems.

4. Equipment & Test Facility Integration

• Interface with environmental chambers, chillers, and programmable power sources (via SCPI, CAN, GPIB, Ethernet, RS-232).
• Configure test stands ensuring safety clearances, accessibility, and reliability.
• Manage power distribution racks, coolant loops, and cable routing within test setups.

5. Reliability & Environmental Testing

• Plan and execute reliability tests such as PTCE, HTOE, HTHE, and IP sealing validation.
• Design and adapt fixtures for thermal cycling, humidity, and load endurance.
• Analyze degradation and failure modes, providing design feedback to engineering teams.
• Correlate test data with real-world usage to accelerate validation cycles.

6. Validation, Calibration & Quality Assurance

• Verify fixture functionality—mechanical fit, electrical continuity, and sensor calibration.
• Perform fixture checkout and validation before test campaigns.
• Maintain calibration schedules and track fixture health over long-term use.
• Enforce safety standards (HV protection, grounding, insulation integrity).

Qualifications & Skills

• Bachelor's or Master's Degree in Mechanical, Electrical, or Mechatronics Engineering.
• 3–7 years of experience in test fixture design, validation, or lab-based engineering.
• Proficiency with SolidWorks or equivalent CAD software.
• Working knowledge of Python or similar scripting language for test automation.
• Experience with NI DAQ systems, programmable power supplies, and environmental chambers.
• Understanding of HV safety, mechanical stress analysis, and reliability testing.
• Strong troubleshooting and problem-solving abilities with a hands-on approach.
• Familiarity with JIRA, Confluence, or equivalent task tracking tools.

Preferred Experience

• EV or high-voltage component testing.
• Exposure to environmental/reliability standards (PTCE, HTOE, IP).
• Experience in data acquisition, signal integrity, and test automation frameworks.
• Strong ownership mindset with ability to balance speed, safety, and standardization.