Mechatronic Design And Release Engineer - Consumer Charging

In this position...

The engineer is accountable for all product deliverables necessary to provide a high-quality solution to their assigned vehicle program, from initial design through production launch. A key aspect of this role involves designing, developing, and implementing comprehensive mechatronic and power electronics test setups and creating detailed test cases to thoroughly validate system performance, power delivery, thermal behavior, reliability, and compliance with all specifications. This includes both bench-level and vehicle-level validation, often requiring the development of custom tools and methodologies to ensure optimal system robustness and electrical safety.

Mechatronic Design and Release Engineer - Consumer Charging The Mechatronic Design and Release Engineer is responsible for the end-to-end development and integration of critical mechatronic consumer charging and power systems, including but not limited to USB data-and-power ports (USB-C Power Delivery), DC-AC power inverters, High Voltage Power Outlets, and Wireless Charging Systems. Because these systems are deployed globally, this role requires a thorough understanding of regional differences in phase, voltage, and frequency standards. These systems are fundamental to customer convenience, work-site and recreational utility, and the overall user experience within Ford's latest vehicle architecture. This role specifically focuses on the robust power electronics, thermal management, and hardware integration of these complex systems, ensuring seamless interface with the vehicle's electrical network and body control modules.

What you'll do...

• Support all vehicle prototype builds, product launch, and service issues related to consumer charging electronic hardware, power electronics, and system-level integration.
• Develop and execute comprehensive test plans, including the creation of original test cases and custom testing tools for both bench and vehicle-level power and thermal validation.
• Perform circuit simulations, power studies, and hardware-level analysis using tools such as LTSpice, MATLAB, and power electronics simulation tools to ensure robust power electronic design.
• Conduct system-level analysis of internal connections, including connectors, relays, contactors, and thermal management of charging and power delivery hardware.
• Lead the troubleshooting and problem-resolution process using vehicle network tools (Vector CANalyzer/CANoe). Collect and analyze data, review system schematics, and evaluate vehicle EDS as required.
• Collaborate closely with Component, Architecture, Systems Engineering teams to ensure hardware/software compatibility and alignment with vehicle electrical and global regulatory requirements.
• Support the development of robust foundation documents, including DFMEA, Design Specifications, D/PVPR, and Worst-Case Circuit Analysis (WCCA).
• Lead technical design reviews for module hardware requirements, power electronics, thermal interfaces, and mechanical/connector interfaces.
• Manage Tier 1 supplier engineering activities on a case-by-case basis to ensure component delivery meets Ford's rigorous quality and timing standards.
• Lead cross-functional teams to drive timely resolution of program-specific engineering issues using failure detection strategies (Fishbone, 8D, etc.).
• Lead the delivery of all engineering requirements for consumer charging mechatronic components per each development milestone, as defined by the Ford product development process.
• Develop solutions to revise or add features to consumer charging and power systems as they impact hardware, thermal performance, and electronic control logic.
• Ensure designs meet electrical safety, functional safety (ISO 26262), and global regulatory standards for consumer-facing power delivery.

What you'll do...

• Support all vehicle prototype builds, product launch, and service issues related to consumer charging electronic hardware, power electronics, and system-level integration.
• Develop and execute comprehensive test plans, including the creation of original test cases and custom testing tools for both bench and vehicle-level power and thermal validation.
• Perform circuit simulations, power studies, and hardware-level analysis using tools such as LTSpice, MATLAB, and power electronics simulation tools to ensure robust power electronic design.
• Conduct system-level analysis of internal connections, including connectors, relays, contactors, and thermal management of charging and power delivery hardware.
• Lead the troubleshooting and problem-resolution process using vehicle network tools (Vector CANalyzer/CANoe). Collect and analyze data, review system schematics, and evaluate vehicle EDS as required.
• Collaborate closely with Component, Architecture, Systems Engineering teams to ensure hardware/software compatibility and alignment with vehicle electrical and global regulatory requirements.
• Support the development of robust foundation documents, including DFMEA, Design Specifications, D/PVPR, and Worst-Case Circuit Analysis (WCCA).
• Lead technical design reviews for module hardware requirements, power electronics, thermal interfaces, and mechanical/connector interfaces.
• Manage Tier 1 supplier engineering activities on a case-by-case basis to ensure component delivery meets Ford's rigorous quality and timing standards.
• Lead cross-functional teams to drive timely resolution of program-specific engineering issues using failure detection strategies (Fishbone, 8D, etc.).
• Lead the delivery of all engineering requirements for consumer charging mechatronic components per each development milestone, as defined by the Ford product development process.
• Develop solutions to revise or add features to consumer charging and power systems as they impact hardware, thermal performance, and electronic control logic.
• Ensure designs meet electrical safety, functional safety (ISO 26262), and global regulatory standards for consumer-facing power delivery.