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.