Principal Electrical Engineer, High Voltage Power Electronics Motor Drives

Irvine, CA

Aerospace is at a turning point — costs are rising, supply chains are strained, and old ways of building can’t keep up. At Neon Aero, we’re breaking that mold. We move fast, think big, and combine start-up agility with aerospace expertise to design, build, and scale aircraft in ways the industry has never seen. Our team leverages automation, AI-driven tools, and a fully connected digital backbone to accelerate innovation and reduce barriers to production.

Here, you won’t just take a job — you’ll help reinvent how the world flies. If you’re ready to solve complex problems, push technology further, and work alongside some of the brightest minds in aerospace, this is your chance to make a real impact.

Neon Aero is seeking a Principal Electrical Engineer in Irvine, California. The Principal Engineer, High Voltage Power Electronics for Motor Drives provides technical leadership in the architecture, design, and qualification of high voltage motor drives for aerospace and advanced mobility applications. This is a deeply hands‑on role: the engineer personally develops architectures, block diagrams, schematics, and the analysis behind them, and owns the rationale for every major design decision across drives from 1 kW to 100 kW, on DC buses from 270 V to 800 V (up to 1000 V), powered by batteries in applications such as eVTOL and by turbogenerator systems.

The role collaborates closely with motor control, embedded software, mechanical, thermal, manufacturing, and supply chain teams, and provides strong technical leadership, ownership, and mentoring of other engineers without direct people management responsibility.

Key Responsibilities

Architecture and Power Stage Design

• Own architecture and design of HV motor drives in two classes: 1 to 3 kW convection-cooled, and 3 to 100 kW liquid or forced-air cooled.
• Design inverter power stages for 270 V to 800 V buses (up to 1000 V): device selection (SiC, GaN, Si), gate drive, protection, and sensing.
• Develop PMSM drive hardware, applying motor control fundamentals to select feedback sensors, current sensing, switching frequency, and processors.
• Design input DM/CM filters and size DC link capacitors for ripple, stability, and lifetime.

EMI, Grounding, and Thermal Design

• Define shielding, grounding, and bonding for motors, cables, and enclosures to contain switching noise.
• Own thermal and EMI design for integrated motor and controller units in a single enclosure.
• Select components, processors, and HV connectors for high‑vibration, extended‑temperature aviation and defense environments.

Analysis, Validation, and Qualification

• Personally perform loss, thermal, stress, derating, insulation, EMI, and worst‑case analyses.
• Develop schematics and review layouts for high dv/dt power stages (creepage, clearance, commutation loops, partial discharge).
• Lead bring‑up, validation, and root cause investigations in the lab.
• Support DO-160 and MIL‑STD‑461 qualification and transition designs into production.

Manufacturing and Mentorship

• Drive DFM, DFT, and DFA; define manufacturing test requirements, coverage, and end‑of‑line test strategy.

Qualifications

• BS or MS in Electrical Engineering or related field; equivalent experience considered.
• Minimum of 12 years designing and shipping power electronics, including multiple motor drives or high power converters.
• Hands‑on design experience at both low power (1 to 3 kW) and high power (up to about 100 kW).
• Direct experience with HV DC buses (270 V to 800 V, up to 1000 V).
• Depth in at least one of automotive, industrial, aviation, or defense at comparable complexity.
• Expertise in inverter power stages, device selection, gate drive, DC link, and EMI filter…