Senior Hardware Test Engineer - Power Electronics for Electric Vehicles

Senior Hardware Test Engineer The Senior Hardware Test Engineer will be responsible for developing and executing validation strategies for Low & high-voltage power electronics products used in electric vehicles. This role combines hardware testing, test automation, Hardware-in-the-Loop (HIL) validation, laboratory development, and cross-functional collaboration. You will work closely with global hardware, software, controls, systems, and manufacturing teams to validate next-generation electrification technologies and support their successful deployment across Ford vehicle programmes. The position requires strong expertise in power electronics testing, automation frameworks, real-time simulation environments, and automotive validation processes. Hardware Testing Develop and execute comprehensive Component PCBA and System-level test plans for Low Voltage and High Voltage systems Electric Vehicle Supply Equipment (EVSE) Onboard Chargers (OBC) DC-DC Converters Inverters High-Voltage Battery Management Systems (HV-BMS) Lead initial Hardware Bring-Up Testing on new PCBA revisions and generate detailed technical reports. Perform EMI/EMC testing on development hardware and provide direct technical feedback to the HW Design team. Define validation requirements, test methodologies, success criteria, and acceptance metrics. Support Design Verification Plan & Report (DVP&R) development and execution. Test Automation Development Develop and maintain HW bench-level test automation scripts using Python (and/or NI LabVIEW) to improve test efficiency, repeatability, and logging.Create automated test scripts to improve test efficiency, repeatability, and reporting. Lead Tester Board design and development, including custom test fixtures, wiring harnesses, and instrumentation setups. Perform MATLAB circuit simulations to verify and optimize tester board designs before build. Integrate power electronics hardware with real-time simulation systems and controllers. Develop custom test fixtures, wiring harnesses, and instrumentation systems. Quality & Problem Resolution Analyse test results to identify failure modes, root causes, and design improvement opportunities. Prepare and review system-level DFMEAs in close alignment with Cross-Functional Teams (CFT). Generate detailed technical reports and validation documentation. Troubleshoot automated test systems, instrumentation, and hardware-software integration issues. Support issue resolution activities with design, controls, and systems engineering teams. Cross-Functional Collaboration Collaborate with global hardware, software, controls, systems engineering, and manufacturing teams. Participate in design reviews and provide recommendations related to testability, reliability, and product performance. Support programme milestones and validation deliverables across global vehicle programmes. Interface with stakeholders across multiple time zones to align validation strategies and programme schedules. Required Qualifications Bachelor's or Master's degree in Electrical Engineering, Electronics Engineering, Computer Engineering, Mechatronics Engineering, or a related field. 5 + years of experience in hardware testing and validation of power electronics systems such as: Onboard Chargers (OBC) Inverters DC-DC Converters Motor Drives Battery Management Systems EV Charging Equipment Strong understanding of power electronics fundamentals, including: IGBT, MOSFET, and Silicon Carbide (SiC) devices Gate driver circuits Power conversion architectures Thermal management EMI/EMC principles Hands-on experience with laboratory equipment including: Oscilloscopes Power analysers Electronic loads AC/DC power supplies Environmental chambers Strong proficiency in Python for test automation, scripting, and data analysis. Working knowledge of automotive EMC and electrical validation standards. Basic understanding of embedded systems and firmware interactions. Strong analytical, troubleshooting, and problem-solving skills. Excellent verbal and written communication skills. Experience mentoring or guiding junior engineers. Preferred Qualifications Hands-on experience with Python/ NI LabVIEW for automated test system development. Experience in Tester Board design and circuit simulation using MATLAB/Simulink. Familiarity with Test Stand, SQL, or similar test data management tools. Experience supporting automotive electrification or energy management products. Knowledge of ISO 26262 Functional Safety requirements. Familiarity with automotive communication protocols such as CAN. Knowledge of automotive and regulatory standards including AIS, IEC, ISO, and UL standards. Experience collaborating with global engineering teams and suppliers. Experience Level Senior Level