Mechatronic Design and Release Engineer – Consumer Charging

Ford; Dearborn (MI); Hybrid; USD 65,000 - 166,000; Full time

Benefits offered by this job

Vehicle discount program for employees

Tuition assistance

Flexible hybrid work

Job summary

Ford is seeking a skilled mechatronics/electrical engineer in Dearborn to drive design, validation, and integration of consumer charging hardware and power electronics across vehicle programs. You will create test setups, develop tools, and ensure safety, reliability, and compliance from design through production launch.

Key focus areas include bench and vehicle validation, HIL testing, and collaboration with DR teams to align hardware and software with global standards.

Qualifications

• BSEE or MS in Mechatronics Engineering preferred; other disciplines may be considered with relevant experience.
• 5+ years in automotive design or electronic hardware development.
• Proficient in MATLAB, LTSpice, Mathcad, and power electronics simulation tools.
• Strong knowledge of Vector CANalyzer/CANoe and diagnostic hardware.
• Experience with HIL testing and custom test scripts.
• FMEA, 8D, and other structured problem‑solving methods.
• Familiar with USB-PD, Qi, LIN, and global electrical standards.
• ISO 26262 and electrical safety awareness.
• Excellent communication and cross-functional leadership.

Responsibilities

• Support vehicle prototype builds and resolve service issues related to charging hardware.
• Develop and execute test plans and tools for bench and vehicle validation.
• Perform circuit simulations and power studies to validate designs.
• Analyze internal connections, relays, connectors, and thermal management.
• Lead troubleshooting using Vector CANalyzer/CANoe and review EDS.
• Collaborate with DR teams to ensure hardware/software compatibility.
• Develop foundation documents: DFMEA, Design Specifications, WCCA.
• Lead design reviews for hardware requirements and interfaces.
• Manage Tier 1 supplier activities to meet quality and timing.
• Lead cross-functional teams to resolve program engineering issues.
• Deliver engineering requirements for consumer charging modules per milestones.
• Develop features for charging/power systems affecting hardware and safety.
• Ensure designs meet electrical safety and ISO 26262 standards.

Skills

Mechatronics

Power electronics

Vector CAN tools

HIL testing

Test scripting

8D problem solving

FMEA

PCB design

ISO 26262

Education

BSEE or MS in Mechatronics Engineering

Tools

MATLAB

LTSpice

Mathcad

PLECS

Saber

Simscape Electrical

Vector CANalyzer

CANoe

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.

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 childcare 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 5-8, and ranges from $65,100-$166,200.

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.

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.