System Test Engineer -Battery Systems

Job Title:

Systems Test Engineer – Battery Systems

Location:

Milwaukee Wisconsin
Job Type: Full-Time

Job Summary

We are seeking a highly skilled Systems Test Engineer to define, develop, integrate, and validate Li-ion and ultra capacitor battery systems for 12V–48V automotive applications. This role is responsible for ensuring system compliance with OEM specifications and regulatory requirements while leading system-level integration, verification, and validation activities.
The ideal candidate will have strong hands-on experience with battery systems, power electronics, and automotive validation processes, and will work cross-functionally with electrical, mechanical, thermal, and software teams to deliver robust, production-ready energy storage solutions.

Key Responsibilities
Define, develop, and integrate Li-ion and ultra capacitor energy storage systems in compliance with OEM and regulatory standards.
Apply in-depth knowledge of Li-ion battery system functionality, safety, and performance to support system design and validation.
Define electrical, thermal, and mechanical interfaces between battery packs, ultra capacitor modules, and Battery Management Systems (BMS).
Lead and execute Design Verification (DV) and Production Validation (PV) activities.
Develop, maintain, and execute Design Verification Plans and Reports (DVP&R) to ensure comprehensive system validation.
Support Hardware-in-the-Loop (HiL), Software-in-the-Loop (SiL), and system-level validation activities.
Perform system lifecycle studies, thermal modeling, and electrical load analysis for predictive performance assessment.
Develop and execute system integration, verification, and validation plans.
Execute system-level tests, analyze results, and drive root cause analysis and issue resolution.
Act as a technical liaison across systems, electrical, mechanical, thermal, software, and safety engineering teams.
Support DFMEA, system safety processes, failure analysis, and design reviews.
Interface with OEM customers to ensure technical alignment and successful program execution.
Prepare and maintain technical documentation, test procedures, and validation reports.

Required Qualifications & Skills
Hands-on experience with system integration and testing of power electronics, such as DC-DC converters and battery systems.
Strong understanding of Li-ion battery and/or ultra capacitor technologies.

Experience with low-voltage automotive energy storage systems (12V–48V).
Knowledge of automotive communication protocols such as CAN and LIN.
Proficiency with requirements management and validation tools (e.g., Jama, IBM DOORS).
Familiarity with automotive standards, functional safety (ISO 26262), and regulatory requirements.
Strong understanding of the V-Model development process, especially verification and validation phases.
Experience using test and validation equipment such as:
Oscilloscopes
Power analyzers
CAN tools
Data loggers
Ability to interpret electrical schematics, system requirements, and test data.

Experience with Battery Management Systems (BMS) and/or power conversion modules.
Background in DFMEA, DVP&R, and system safety processes.

Experience with environmental, mechanical, and electrical testing associated with Li-ion battery and ultra capacitor systems.

Preferred Qualifications (Optional)
Experience working directly with automotive OEMs or Tier-1 suppliers.
Knowledge of thermal simulation tools and electrical system modeling software.

Experience with regulatory testing (EMC, vibration, thermal shock, abuse testing).
Familiarity with ASPICE or other automotive development process frameworks.