Mechatronic Design and Release Engineer - Consumer Charging

Ford; Dearborn (MI); On-site; USD 120,000 - 180,000; Full time

Job summary

Ford is seeking an experienced Mechatronics/Electrical engineer to drive power electronics validation for consumer charging systems. You will design, develop, and implement test setups, validate performance and thermal behavior, and create robust tools for bench and vehicle testing.

You will lead cross-functional reviews, manage supplier activities, and ensure compliance with electrical safety and ISO standards while supporting production launches and problem resolution across the DR community.

Qualifications

• BSEE (MSEE) or MS in Mechatronics preferred.
• 5+ years in automotive design and release or electronic hardware development.
• Experience with simulation and analysis tools such as MATLAB, LTSpice, and power electronics tools.

Responsibilities

• Support vehicle prototype builds, product launches, and service issues related to charging electronics and power delivery hardware.
• Develop and execute comprehensive test plans for bench and vehicle-level validation of power and thermal performance.
• Perform circuit simulations and hardware-level analysis to ensure robust power electronic design.
• Lead troubleshooting using vehicle network tools (Vector CANalyzer/CANoe) and analyze data.
• Collaborate with cross-functional teams to ensure hardware/software compatibility and safety compliance.
• Lead design reviews for module hardware, thermal interfaces, and connectors.
• Manage Tier 1 supplier activities to meet quality and timing standards.
• Deliver engineering requirements per Ford product development process.

Skills

Automotive hardware design

Power electronics

Circuit simulation

Test development

Embedded systems

Education

BSEE or MS in Mechatronics

5+ years in automotive hardware development

Engineering fundamentals in electrical safety

Tools

MATLAB

LTSpice

PLECS / Saber / Simscape

Vector CANalyzer/CANoe

Oscilloscopes / Multimeters

Job description

In this position...
The engineer is accountable for all product deliverables necessary to provide a high-quality solution to their assigned vehicle program, from initial design through production launch. A key aspect of this role involves designing, developing, and implementing comprehensive mechatronic and power electronics test setups and creating detailed test cases to thoroughly validate system performance, power delivery, thermal behavior, reliability, and compliance with all specifications. This includes both bench-level and vehicle-level validation, often requiring the development of custom tools and methodologies to ensure optimal system robustness and electrical safety.

What you'll do...

• Support all vehicle prototype builds, product launch, and service issues related to consumer charging electronic hardware, power electronics, and system-level integration.


• Develop and execute comprehensive test plans, including the creation of original test cases and custom testing tools for both bench and vehicle-level power and thermal validation.


• Perform circuit simulations, power studies, and hardware-level analysis using tools such as LTSpice, MATLAB, and power electronics simulation tools to ensure robust power electronic design.


• Conduct system-level analysis of internal connections, including connectors, relays, contactors, and thermal management of charging and power delivery hardware.


• Lead the troubleshooting and problem-resolution process using vehicle network tools (Vector CANalyzer/CANoe). Collect and analyze data, review system schematics, and evaluate vehicle EDS as required.


• Collaborate closely with Component, Architecture, Systems Engineering teams to ensure hardware/software compatibility and alignment with vehicle electrical and global regulatory requirements.


• Support the development of robust foundation documents, including DFMEA, Design Specifications, D/PVPR, and Worst-Case Circuit Analysis (WCCA).


• Lead technical design reviews for module hardware requirements, power electronics, thermal interfaces, and mechanical/connector interfaces.


• Manage Tier 1 supplier engineering activities on a case-by-case basis to ensure component delivery meets Ford's rigorous quality and timing standards.


• Lead cross-functional teams to drive timely resolution of program-specific engineering issues using failure detection strategies (Fishbone, 8D, etc.).


• Lead the delivery of all engineering requirements for consumer charging mechatronic components per each development milestone, as defined by the Ford product development process.


• Develop solutions to revise or add features to consumer charging and power systems as they impact hardware, thermal performance, and electronic control logic.


• Ensure designs meet electrical safety, functional safety (ISO 26262), and global regulatory standards for consumer-facing power delivery.

You'll have...

• BSEE (MSEE) or MS in Mechatronics Engineering preferred. Other disciplines may be considered if the candidate has comparable job experience.


• 5+ years of experience in automotive Design and Release (DR) or electronic hardware development.


• Expertise in simulation and analysis tools: MATLAB, LTSpice, Mathcad, and power electronics simulation tools (e.g., PLECS, Saber, or Simscape Electrical).


• Advanced proficiency with Vector tools (CANalyzer, CANoe) and diagnostic hardware (Oscilloscopes, Multimeters, Power Analyzers, Thermal Imaging Cameras).


• Strong background in mechatronic and power electronic systems, including connectors, relays, contactors, and thermal management hardware.


• Experience in developing custom test scripts or hardware-in-the-loop (HIL) testing setups.


• Strong analytical skills (including 8D, 6-Panel, FMEA) and experience with electronic circuit design and board layout.


• Familiarity with consumer charging standards and protocols, including USB-IF / USB-C Power Delivery (PD), Qi (WPC) wireless charging, and LIN.


• Knowledge of global electrical standards, including regional differences in phase, voltage, and frequency.


• Understanding of electrical safety standards and high voltage safety interlocks (UL, IEC).


• Excellent communication and leadership skills for cross‑functional cooperation across the DR community.

Even better, you may have...

• Master's degree in electrical engineering.


• 10+ years of experience in electronic circuit design or power electronics within the automotive industry.


• Familiarity with the Production Part Approval Process (PPAP).


• Proficiency with Ford product development system applications (e.g., WERS, FEDEBOM, Team Center, Integrator, 3DX, etc.).


• Proficiency with model-based systems engineering tools (e.g., MagicDraw / SysML).


• Solid understanding of EMC specifications and mitigation techniques.


• In-depth knowledge of the automotive product development lifecycle (e.g., Ford GPDS) from concept to mass production.


• Experience with PCB design and manufacturing processes.


• Experience with functional safety (ISO 26262) for power delivery systems.

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