F01 - Design Release Engineer – High Voltage Systems

Dorleco; San Francisco (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

Dorleco is seeking a highly technical Design Release Engineer to own the development and validation of our vehicle High Voltage electrical distribution system, focusing on HV busbars, battery interconnects, and wiring harnesses.

You will lead 3D routing, packaging, and 2D print generation, and you will author DFMEA, DVP&R, and engineering specifications while ensuring regulatory compliance for safe high-voltage systems.

Qualifications

• Direct experience in high-voltage vehicle electrical distribution systems.
• Strong understanding of HV busbars, battery interconnects, and wiring harnesses.
• Familiarity with automotive standards like USCAR, LV214/LV215, ISO 26262.
• Hands-on validation testing experience (environmental, mechanical, electrical).

Responsibilities

• Own development and validation of HV electrical distribution system.
• Lead 3D routing, packaging, and documentation for high-power paths.
• Create and maintain DFMEA, DVP&R, and engineering specifications.
• Ensure regulatory and safety compliance for high-voltage systems (isolation, creepage, shielding).

Skills

HV Architecture Design

3D Routing & Integration

DFMEA & DVPR

Regulatory & Safety Compliance

High-Voltage Vehicle Wiring

Busbar & Battery Systems

Automotive Standards

Validation Testing

Tools

Siemens Capital

CATIA

NX

Job description

Position Overview

We are looking for a highly technical Design Release Engineer (DRE) to own the development and validation of our vehicle High Voltage (HV) electrical distribution system. In this role, you will focus strictly on the engineering, 3D routing, and physical architecture of HV busbars, battery interconnects, and HV wiring harnesses.

Core Technical Responsibilities

HV Architecture Design: Lead the design and packaging of HV wiring harnesses (400V-800V+), continuous copper/aluminum busbars, and cell-to-module battery interconnects.

3D Routing & Integration: Own 3D CAD routing, clearance management, and 2D print generation for high-power distribution paths using Siemens Capital, CATIA, or NX.

Technical Engineering Documentation: Author and execute technical documentation including DFMEA, DVP&R, and engineering specifications.

Regulatory & Safety Compliance: Implement high-voltage isolation, creepage/clearance requirements, fusing strategies, shielding, and EMC mitigation techniques.

Required Technical Skills

Vehicle EDS Expertise: Direct experience engineering high-voltage vehicle electrical distribution systems, including high-power connectors, shielding, and crimping tech.

Busbar & Battery Systems: Deep mechanical and electrical understanding of rigid/flexible busbars and thermal management within battery packs.

Industry Standards: Practical knowledge of automotive standards like USCAR, LV214/LV215, ISO 26262, and high-voltage safety regulations.

Validation Testing: Hands-on experience with environmental, mechanical, and electrical testing (insulation resistance, thermal cycling, high-pot test).