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