Senior High Voltage Electronics Engineer

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

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

Life and Disability insurance

Educational assistance

Paid time off

Job summary

Methode Electronics is seeking a Senior High Voltage Electronics Engineer in Michigan to lead a technical team in designing, developing, and validating next‑generation high-efficiency power conversion systems. You will guide hardware architecture, planar transformer design, and PCB development from concept to production.

The role requires 5+ years in HV hardware, strong thermal management expertise, and leadership experience across cross-functional teams.

Qualifications

• Bachelor’s degree in electrical engineering (master’s or Ph.D. preferred).
• 5+ years in high-voltage hardware and board design with project leadership.
• Proven thermal management experience for high-power electronics, including PCB cooling strategies and heat sink integration.
• Demonstrated strategic technical and market strategy development and implementation.
• Direct experience designing, optimizing, and manufacturing planar transformers.
• 4+ years leading, mentoring, or managing engineering teams.
• Proven success designing multi-layer PCBs for 400V to 1kV+ environments.
• Proficiency with Altium Designer or Cadence Allegro, alongside thermal simulation software.
• Strong knowledge of safety and manufacturing specs (IPC-2221, IPC-2152, UL 60950/62368).

Responsibilities

• Guide cross-functional technical teams from concept to production.
• Design advanced thermal solutions for high-power density PCBs.
• Integrate active and passive cooling systems.
• Design and optimize planar transformers and planar inductors for high-frequency HV power converters.
• Lead HV PCB layout architectures with embedded winding structures.
• Establish creepage, clearance, and isolation boundaries per safety standards.
• Simulate circuits, magnetics, and thermal performance using SPICE, PLECS, and thermal tools.
• Create schematics and oversee multi-layer, high-density HV PCB designs.
• Lead hardware testing, debugging, and compliance validation under extreme thermal conditions.

Skills

High-Voltage Hardware

PCB Design

Planar Magnetics

Altium/Cadence

Thermal Management

Safety Standards IPC

Leadership

Multi-layer PCBs

Thermal Simulation

Education

Bachelor’s degree in Electrical Engineering

Master’s or PhD preferred

Tools

Altium Designer

Cadence Allegro

Ansys Icepak

Flotherm

Job description

Summary

We are seeking an experienced Senior High Voltage Electronics Engineer to lead a technical team in designing, developing, and validating next-generation, high-efficiency power conversion systems. You will serve as both a technical authority and a team leader, guiding hardware architecture and driving planar transformer design, advanced thermal management, high-voltage component selection, and printed circuit board (PCB) development from concept to production.

Key Responsibilities

• Guide, mentor, and align cross-functional technical teams (software, mechanical, layout) to execute complex engineering projects from concept to production.
• Design advanced thermal solutions for high-power density PCBs, including thermal vias, heavy copper tracking, and insulation materials.
• Integrate active and passive cooling systems such as heat sinks, liquid cooling cold plates, or thermal interface materials (TIMs).
• Design and optimize planar transformers and planar inductors for high-frequency, high-voltage power converters.
• Lead high-voltage PCB layout architectures, integrating embedded winding structures for planar magnetics.
• Establish creepage, clearance, and isolation boundaries per safety standards.
• Simulate circuits, magnetics, and thermal performance using SPICE, PLECS, and thermal analysis tools (e.g., Ansys Icepak, Flotherm).
• Create schematics and oversee multi-layer, high-density, high-voltage PCB designs.
• Lead hardware testing, debugging, and compliance validation under extreme thermal conditions in the lab.

Required Qualifications

• Education: Bachelor’s degree in electrical engineering (master’s or Ph.D. preferred).
• Experience: Minimum of 5+ years in high-voltage hardware. board design and project leadership.
• Thermal & Cooling Design Expertise: Proven success in thermal management for high-power electronics, including PCB cooling strategies and heat sink integration.
• Strategic Thinking; Demonstrated strategic technical and market strategy development and implementation.
• High Familiarity with Planar Magnetics: Direct experience designing, optimizing, and manufacturing planar transformers.
• Leadership Skills: At least 4+ years of experience leading, mentoring, or managing engineering teams.
• PCB Expertise: Proven success designing multi-layer PCBs for 400V to 1kV+ environments.
• Tools: Proficiency with Altium Designer or Cadence Allegro, alongside thermal simulation software.
• Standards: Strong knowledge of safety and manufacturing specs (IPC-2221, IPC-2152, UL 60950/62368).

Preferred Skills

• Experience with FEA/CFD simulation tools for thermal analysis like Ansys Icepak, Flotherm, or SolidWorks Flow Simulation.
• Knowledge of advanced substrate materials like Insulated Metal Substrates (IMS) or ceramic PCBs (AlN, Al2O3).
• Experience mitigating partial discharge and arcing risks in dense board and planar winding designs.
• Background in automotive EV powertrain systems or renewable energy grid storage.
• Strong understanding of electromagnetic compatibility (EMC) and EMI mitigation.

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.

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.

Equal Opportunity

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.

About Us

Methode Electronics is a leading developer of custom-engineered and application-specific products and solutions utilizing the latest technologies. From magnetic signature sensing of mechanical and electrical properties to the revolutionary solid-state touch sensitive switches used in today's appliances and automobiles, Methode's extensive toolbox of technical solutions help our customers differentiate their products. Our regional design and customer support centers, coupled with manufacturing campuses in the Americas, Europe, and Asia allow Methode to bring a total business solution to customers worldwide. We leverage the talents of our over 5,000 employees to serve a diversified group of customers in four market areas: User Interfaces, Sensor and Switches, Power and Data. Methode helps customers win in their end markets by providing an unmatched combination of customer focus, differentiated technology, problem solving and world‑class manufacturing.