High Voltage Systems Engineer

Methode Electronics, Inc.; Southfield (MI); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Medical, dental, vision, hearing, life

401(k) with company contribution

Paid time off

Job summary

Methode Electronics in the United States is seeking a Senior High Voltage Systems Engineer to lead design, development, and testing of high‑voltage architectures for next‑gen EV powertrains. You will architect 800V DC‑DC converters, planars, and power boards, collaborating across software, mechanical, and layout teams to deliver safe, reliable systems.

The role requires 5+ years in HV systems, deep knowledge of planar magnetics, thermal management, and automotive safety standards (ISO 26262).

Qualifications

• 5+ years hands-on experience developing high‑voltage systems exceeding 60V (ideally 400V–800V+)
• Experience with switching topologies, gate driver optimization, and magnetic component design
• Thermal management experience with liquid cooling or phase‑change cooling for high‑power electronics
• Familiarity with IPC-2221, IPC-9592 and automotive safety frameworks (ISO 26262/ASIL)
• Proficiency in MATLAB/Simulink, PLECS, PSpice or magnetic simulation tools and lab instruments
• Strong leadership and cross‑functional collaboration skills

Responsibilities

• Architect, design, and optimize 800V DC‑DC converters, onboard chargers, and traction inverters using wide‑bandgap semiconductors
• Design planar transformers and inductors to maximize power density and minimize parasitics
• Integrate power boards and multi‑layer PCBs within vehicle powertrain or grid system
• Perform thermal analysis and design active cooling solutions for high‑power modules
• Conduct system simulations, stress modeling, and FEA for magnetic flux optimization
• Lead hardware validation of HV batteries, inverters, and cabling harnesses in lab settings
• Guide cross‑functional teams to execute projects from concept to production
• Ensure safety with isolation monitoring, interlocks, and creepage/clearance requirements
• Troubleshoot hardware issues related to power flow, EMI/EMC, and component reliability

Skills

Power electronics design

High voltage systems

Planar magnetics design

Thermal management

Automotive safety knowledge

Leadership / project management

Education

Bachelor’s or Master’s degree in Electrical Engineering or Power Electronics

Tools

MATLAB/Simulink

PLECS

PSpice

ANSYS Maxwell

Job description

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 characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of this job.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. The employee must occasionally lift and/or move up to 25 pounds. Frequent hand motion and repetitive tasks including using a computer for typing. While performing the duties of this job, the employee will occasionally do immediate reaching and overhead reaching to perform various duties, frequent standing for varied amounts of time to perform various duties, frequent walking for varied amounts of time to perform various duties. Squat or bend to perform various duties. Occasionally climb stairs.

Benefits and Perks

Methode offers U.S. employees comprehensive benefits including Medical, Dental, Vision, Hearing, Life and Disability insurance, educational assistance, and paid time off benefits. Voluntary benefit plans include Accident, Hospital Indemnity, and Pet Insurance coverage. Employees also have access to valuable discount programs that can contribute to lowering costs off certain technology, automotive, and home appliance products. In addition, Methode provides an Employee Assistance Program (EAP) and participation in the Company's 401(k) plan, which includes a company contribution.

Methode Electronics is an equal opportunity employer. We evaluate qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, genetic information and other legally protected characteristics per the EEO Poster available here . If you need a reasonable accommodation because of a disability for any part of the employment process, please send an e‑mail to [e-mail] or call [phone] and let us know the nature of your request and your contact information.