BMS Hardware Development Engineer

Ford; Dearborn (MI); Hybrid; USD 115,000 - 193,000; Full time

Benefits offered by this job

Medical, dental, vision coverage

Parental leave

Vehicle discount program

Tuition assistance

Paid time off

Job summary

Ford in Dearborn, MI is seeking a High-Voltage Battery Monitoring System Hardware Engineer to lead design, development, validation, and release of battery monitoring hardware for EV programs. You will own critical monitoring architecture, including cell sensing, current sensing, isolation monitoring, and fault detection.

The ideal candidate has strong analog/mixed-signal hardware design experience, PCB development, and safety-focused engineering.

Qualifications

• BS in Electrical/ Electronics/ Computer Engineering or related field.
• 5+ years in battery systems, high-voltage hardware design, or related work.
• Hands-on hardware design, validation, and safety-focused engineering.
• Experience with analog/mixed-signal circuits, sensors, protection, or power electronics support.

Responsibilities

• Define and develop the battery monitoring hardware architecture for HV applications.
• Design and release hardware for high-capacity energy systems including sensing, balancing, precharge/discharge, isolation monitoring, and fault protection.
• Own the electrical architecture from concept through release; produce schematics, PCB layouts, BOMs, and test docs.
• Perform Worst Case Circuit Analysis and document margins, assumptions, mitigations.
• Support bring-up and validation across board, module, pack, and system levels.
• Create hardware test plans, fixtures, collect data, and drive design improvements.
• Collaborate with firmware, controls, power conversion, and validation teams on interfaces and diagnostics.

Skills

High-voltage hardware design

Analog & mixed-signal design

PCB design & release

WCCA & tolerance analysis

Hardware bring-up & validation

Education

Bachelor's in Electrical Engineering

Tools

CAN interfaces

SPI interfaces

PCB design tools

Job description

The High-Voltage Battery Monitoring System (BMS) Hardware Engineer will lead the design, development, validation, and release of battery monitoring hardware for our advanced EV and high-voltage battery programs, working closely with core automotive engineering and specialized technical teams. This role owns critical elements of the monitoring architecture, including cell voltage and temperature sensing, current sensing, balancing, isolation monitoring, contactor and precharge support, and fault detection.

The ideal candidate brings strong experience in high-voltage battery electronics, analog and mixed-signal hardware design, PCB development, worst-case circuit analysis, hardware validation, and safety-focused engineering. This person will translate system requirements into robust hardware designs and help ensure safe, reliable, manufacturable battery monitoring solutions for high-capacity energy applications.

What you'll do...

• Define and develop the battery monitoring hardware architecture, including centralized, distributed, or modular sensing topologies, multi-pack and system-level monitoring, HV bus protection, and hardware hooks for controls and diagnostics.
• Design and release hardware for high-capacity energy applications, including sensing circuits, balancing circuitry, precharge and discharge circuits, contactor interfaces, isolation monitoring support, current sensing, and protection features.
• Own the electrical architecture and detailed hardware design of the monitoring subsystem from concept through release.
• Author and release engineering artifacts including schematics, PCB layouts, BOMs, assembly drawings, test documentation, and engineering change records.
• Perform Worst Case Circuit Analysis (WCCA) for critical circuits and document margins, assumptions, and mitigations.
• Support board-, module-, pack-, and system-level bring-up and validation.
• Create and execute hardware test plans, design fixtures, collect and analyze data, and drive design improvements.
• Work closely with firmware, systems, controls, power conversion, integration, and validation teams to define and verify hardware/software interfaces, ADC timing, sampling strategies, communications, diagnostics, and fault handling behavior.
• Support safety and compliance activities, including requirements derivation, traceability, FMEA/FMEDA, hazard analysis, and verification evidence.
• Drive root-cause analysis for design, manufacturing, commissioning, and field issues; define and implement corrective actions.
• Optimize designs for cost, manufacturability, testability, serviceability, and supply chain robustness.
• Evaluate and qualify components, support supplier discussions, and assist with prototype builds and production release activities.
• Partner with manufacturing and test engineering teams on production test plans and automated test fixtures.
• Document technical decisions, validation results, and risk mitigation plans; participate in technical reviews and cross-functional presentations.

You'll have...

• Bachelor’s degree in Electrical Engineering, Electronics Engineering, Computer Engineering, or a related technical field.
• 5+ years of experience in battery systems, battery electronics, high-voltage hardware design, or related technical work.
• Hands‑on experience designing and validating hardware for battery monitoring, BMS, or high‑voltage energy storage systems.
• Experience with analog and mixed‑signal circuit design, sensor interfaces, protection circuitry, or power electronics support circuits.
• Experience performing hardware debug, validation, and root‑cause analysis in lab and prototype environments.
• Experience working cross‑functionally with systems, firmware, test, manufacturing, and supplier teams.
• Strong written and verbal communication skills.
• Ability and willingness to travel occasionally.

Even better, you may have...

• Master’s degree in Electrical Engineering or a related technical field.
• Experience in BESS, automotive HV battery systems, or other high‑voltage energy storage applications.
• Experience with centralized, distributed, or modular BMS architectures and monitoring topologies.
• Experience with cell monitoring ICs, isolation monitoring, balancing circuitry, contactor control, and diagnostic hardware.
• Experience with WCCA, FMEA, FMEDA, and product safety development processes.
• Experience with board-, module-, rack-, and system-level hardware validation.
• Familiarity with CAN, SPI, and other battery system communication interfaces.
• Experience supporting production launch, manufacturing test, and supplier quality resolution.
• Technical Skills
  • Analog and mixed‑signal circuit design
  • High‑voltage battery monitoring hardware architecture
  • Centralized, distributed, or modular BMS topologies
  • PCB design and release tools
  • Worst Case Circuit Analysis (WCCA) and tolerance stack analysis
  • Hardware bring‑up, validation, and failure analysis
  • Test fixture development and data acquisition
  • Functional safety and diagnostic coverage concepts
  • Requirements traceability and engineering change control
  • Cross‑functional interface management
  • Manufacturing support and production readiness
  • CAN, SPI, and related interface fundamentals
• Location & Travel
  • Location: Dearborn, MI/Hybrid
  • Travel: Occasional travel required.

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp‑up programs, subsidized back‑up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 7 and ranges from $99,600-$166,600.,

This position is a salary grade 8 and ranges from $115,000-$192,900.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Internal applicants: moving into this role may result in an adjustment to your current compensation based on the posted pay range for this role, taking into consideration your qualifications and other relevant factors.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire. We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid with a requirement to be onsite four or more days per week.