Thermal Engineer

Base pay range

$60.00/hr - $80.00/hr

Job Title: Thermal Test Engineer – High Voltage / Power Electronics Test Engineer

Job Summary: The engineer will own the validation of high‑voltage power electronic systems, with a focus on thermal characterization, electrical performance, and long‑term reliability. This role involves designing test systems and procedures, executing qualification and reliability tests, and providing data‑driven feedback to improve product design and ensure compliance with relevant safety and industry standards.

• Design, build, instrument, and automate test setups/fixtures for electrical, thermal, and mechanical testing of high‑voltage power electronics (inverters, DC‑DC converters, onboard chargers, power modules).
• Develop and execute test plans for performance, thermal behavior, and reliability across prototype, pre‑production, and production stages, including temperature rise, thermal cycling, and accelerated life tests.
• Validate electrical and thermal characteristics (efficiency, losses, junction and case temperatures, hotspot identification) under worst‑case operating conditions and various load profiles.
• Perform high‑voltage tests such as applied/induced voltage, insulation, partial discharge, and dielectric withstand in line with IEC/UL/EN safety standards (e.g., IEC 61010‑1, IEC/UL 62368‑1).
• Conduct reliability and environmental tests (thermal shock, thermal cycling, damp heat, vibration, burn‑in) to assess long‑term robustness and failure modes of power electronic assemblies.
• Collect, analyze, and interpret test data; perform root‑cause analysis on failures and work with design, reliability, and manufacturing teams to define corrective actions.
• Develop and maintain automated test scripts and data acquisition routines using lab instrumentation and software tools (oscilloscopes, power analyzers, DAQs, LabVIEW/Python/MATLAB or similar).
• Define and document test procedures, acceptance criteria, and test reports for design validation, product qualification, and manufacturing test specifications.
• Collaborate closely with hardware, firmware, and systems engineers to understand design intent, define test requirements, and feed back test results into design iterations.
• Support factory and field issues by reproducing problems in the lab, conducting structured experiments, and providing clear technical documentation and recommendations.

• Bachelor’s degree in Electrical Engineering, Power Electronics, Electronics, or related field;
  Master’s degree preferred for more senior roles.
• 3–7+ years (adjust per level) of hands‑on test or validation engineering experience with high‑voltage/high‑power electronic systems (e.g., traction inverters, chargers, DC‑DC, UPS, solar inverters, motor drives).
• Solid understanding of power electronics principles (switch‑mode converters, inverters, magnetics, power semiconductors such as Si/SiC/GaN) and their thermal behavior.
• Demonstrated experience in thermal measurement and analysis: thermocouples, IR cameras, temperature rise tests, thermal cycling, and related test methods.
• Strong hands‑on lab skills with high‑voltage test equipment: oscilloscopes, multimeters, power supplies, electronic loads, power analyzers, hipot testers, and safety procedures for HV labs.
• Experience with test automation and data analysis tools (e.g., LabVIEW, Python, MATLAB, or similar) and with structured test documentation and reporting.
• Familiarity with relevant standards and guidelines for safety and reliability of power electronics (e.g., IEC 61010‑1, IEC/UL 62368‑1, UL 9540A or application‑specific standards).
• Strong analytical, problem‑solving, and root‑cause analysis skills, with the ability to work independently in a fast‑paced R&D or production environment.
• Effective communication skills to collaborate with cross‑functional teams and present test results to technical and non‑technical stakeholders.

• Experience in reliability engineering and accelerated lifetime testing for power semiconductors and power modules.
• Background in thermal simulation or CFD tools (e.g., FloTHERM, Icepak, COMSOL) to complement empirical testing.
• Prior work on automotive, renewable energy, grid‑tied, or industrial high‑voltage systems with knowledge of associated regulatory and customer requirements.
• Experience defining or supporting manufacturing test specifications and end‑of‑line test systems for power electronic products.

Mid‑Senior level

Contract