Senior Power Module Product Design Engineer

Ford; Long Beach (CA); On-site; USD 140,000 - 190,000; Full time

Benefits offered by this job

Medical coverage

Dental coverage

Vision coverage

Prescription drug coverage

Parental leave

Paid time off

Holidays

Job summary

Ford is seeking a Power Module Product Design Engineer for its EVDD team in California. You will own power modules and the integration into inverter assemblies from concept through production, defining mechanical requirements, 3D modeling, 2D drawings, and critical interfaces such as solder joints and thermal paths.

The role emphasizes hands-on design, analysis, and collaboration with suppliers and in-house manufacturing to ensure robust thermal and mechanical performance of power modules in

Qualifications

• Bachelor's degree in Mechanical Engineering or equivalent.
• 7+ years semiconductor experience focused on power modules.
• Strong fundamentals in engineering principles and problem solving.

Responsibilities

• Own inverter power modules and integration into inverter assemblies from concept through production.
• Define and validate mechanical requirements for power modules including 3D models, 2D drawings, and process specs.
• Design, analyze interfaces between power modules and inverter assemblies (solder joints, laser welds, bolted joints, electrical contacts, thermal interfaces, fluid seals).
• Design, analyze and verify thermal performance of power module assemblies (power modules, heat sinks, etc).
• Design and execute AQG-324 reliability test campaigns and develop lifetime models for power modules.
• Collaborate with semiconductor suppliers to bring thermal/mechanical functionality of power modules to production.

Skills

Semiconductor experience

Power electronics

Finite element analysis

3D CAD

GD&T

Education

Bachelor's Degree in Mechanical Engineering

Tools

CATIA/3DX

Job description

We made history and now we work to transform the future - for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

Ford's Electric Vehicles, Digital and Design (EVDD) team is charged with delivering the company's vision of a fully electric transportation future. EVDD is customer-obsessed, entrepreneurial, and data-driven and is dedicated to delivering industry-leading customer experience for electric vehicle buyers and owners. You'll join an agile team of doers pioneering our EV future by working collaboratively, staying focused on only what matters, and delivering excellence day in and day out. Join us to make positive change by helping build a better world where every person is free to move and pursue their dreams.

In this position

The Power Module Product Design Engineer will be responsible for mechanical functionality of drive unit inverter power semiconductor switches (power modules) and their integration into inverter assemblies.

What you'll do

• Own inverter power modules and their integration into inverter assemblies from concept through production.
• Define and validate the mechanical requirements of power modules for integration in inverter assemblies including 3D models, 2D component / assembly drawings, and engineering process specifications.
• Design, analyze, develop, and verify interfaces between power modules and inverter assemblies including: solder joints, laser welds, bolted joints, electrical contacts, thermal interfaces, and fluid seals.
• Design, analyze, and verify thermal performance of power module assemblies including power modules, heat sinks, and other thermally interfacing components.
• Design and execute AQG-324 reliability test campaigns, analyze the results, and produce lifetime models for power modules.
• Work closely with semiconductor suppliers to define and bring to production the thermal and mechanical functionality of power modules.
• Work closely with in-house manufacturing teams on the design and verification of power module integration and assembly processes.
• Develop manufacturing processes including running DOEs and executing process validation.

You’ll have

• Bachelor's Degree in Mechanical Engineering or equivalent combination of relevant education and experience.
• 7+ years of semiconductor experience with heavy focus on designing, manufacturing, testing, or integrating power modules for use in traction inverter applications.
• Robust foundation in engineering first principles with good engineering judgement.
• Experience using finite element methods for optimizing and validating structural, thermal, and electrical systems.
• Intellectual honesty, curiosity, and humility; a passion for solving deep technical problems; and a drive to deliver engineering excellence. Strong problem solving, analysis, and critical thinking skills.

Even better, you may have

• Strong mechanical design skills including 3D CAD (Catia / 3DX preferred), 2D GD&T, tolerance analysis, and assembly management skills.
• Experience with semiconductor manufacturing processes including soldering, sintering, encapsulation, lead frame assembly, and back-end testing.
• Experience leading technical projects; strong written and verbal communication / presentation / story-telling skills.
• Experience managing or working closely with manufacturing partners, contract manufacturers, and in-house manufacturing teams to bring parts to production.
• Experience leading design / process FMEAs for electronics and/or automotive systems.
• Experience designing and executing durability and design verification campaigns.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care 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 purc