Job Description
As a Magnetics Engineer, you will lead the end-to-end design, simulation, prototyping, and validation of magnetic components integral to our SST product line. This role is crucial in the development of compact, thermally efficient, and manufacturable inductors and transformers capable of operating in medium-voltage, high-frequency environments. The ideal candidate will be equally comfortable working with electromagnetic modelling tools, CAD design platforms, and laboratory test equipment.
Duties and Responsibilities
Magnetic Design and Optimization
Design high-frequency transformers and inductors optimized for power density, thermal management, and EMI performance in SST systems.
Specify winding schemes, insulation strategies, core materials, and mechanical form factors tailored to system-level requirements.
In depth knowledge of safety requirements for transformer construction design including maintaining safety creepage and clearance, insulation class, thermal class and others requirements.
Experienced in the different winding techniques and construction of magnetic component to meet required leakage inductance, bias performance, EMI/EMC and other magnetic parameters.
Modelling and Simulation
Perform 2D/3D finite element analysis (FEA) for electromagnetic field behavior, saturation analysis, core loss estimation, and thermal impact using Ansys or equivalent
Simulate frequency-domain and time-domain behavior using PSIM, LTSpice, PLECS, or equivalent tools.
CAD Design for Magnetics
Support development 3D CAD models and 2D production drawings for custom bobbins, holders, core clamps, and housings using SolidWorks, Inventor, or equivalent tools.
Ensure integration of magnetic parts with the mechanical structure and power stage layout.
Prototyping and Testing
Coordinate prototype builds, including winding processes and fixture design, and perform validation tests (B-H loop, inductance, leakage, Hi-Pot, partial discharge, temperature rise).
Use high-speed data acquisition and thermal imaging tools for in-depth analysis and iterative improvements.
Cross-Functional Collaboration
Work in close coordination with power electronics engineers, system architects, mechanical designers, and test engineers throughout the product development lifecycle.
Support PCB layout optimization and EMI mitigation strategies by advising on magnetic placement and shielding.
Compliance and Documentation
Design magnetics to meet applicable safety, isolation, and thermal standards (e.g., IEC 61869, UL 1446, IEEE).
Maintain detailed documentation of calculations, CAD designs, test results, and BOMs.
Ensure on time release of detailed magnetic design specification for external or internal production
Supplier and Manufacturing Interface
Interface with external vendors and fabrication shops for core materials, winding services, and bobbin production.
Assist with manufacturing feasibility studies, DFM reviews, and cost optimization.
Ensure quality of supplier and its manufacturing facilities to meet the company’s production quality targets
Knowledge, Skills and Abilities
Deep understanding of magnetic materials (ferrite, nanocrystalline, amorphous, powdered iron) and their loss characteristics.
Experienced in the different magnetic construction techniques meeting safety creepage and clearance requirement, insulation class, thermal class, EMI/EMC and leakage inductance requirements while maintaining high efficiency performance.
Solid grasp of transformer theory, leakage minimization, bias performance, core losses, interwinding capacitance effects, and skin/proximity effects.
Familiarity with SST architectures including dual-active bridge (DAB), LLC, and other isolated converter topologies.
Proficiency with electromagnetic FEA software (e.g., ANSYS Maxwell, COMSOL Multiphysics).
High competence with mechanical CAD design for magnetics (e.g., SolidWorks, Creo).
Skilled in using lab instrumentation such as impedance analyzers, thermal cameras, LCR meters, and HV insulation testers.
Strong analytical skills for interpreting simulation and test data to guide design revisions.
Ability to balance trade-offs between performance, cost, thermal limits, manufacturability, and volume.
Ability to work independently, manage multiple projects, and deliver on tight timelines in a fast-paced R&D environment.
Strong technical communication skills for documentation, design reviews, and cross-functional teamwork.
Ability to innovate and apply first-principles thinking to solve novel magnetics challenges.
Qualifications
B.S. or M.S. in Electrical Engineering, Power Electronics, or related field.
5+ years of hands-on experience in magnetics design for high-frequency power conversion.
Expertise in magnetic design, loss analysis, and core material selection.
Experience with CAD tools and electromagnetic simulation platforms.
Familiarity with insulation standards and electrical safety in medium-voltage applications.
Preferred Qualifications:
Background in Solid-State Transformer development or medium-voltage systems.
Experience working with SiC/GaN devices in high-density designs.
Ph.D. or equivalent experience in power magnetics research or product development.
Experience with rapid prototyping and additive manufacturing techniques for bobbins or magnetic formers.
Training
NIL
Work Schedule
Monday to Friday 0830-1730
(Or as required by the project)
Employment Duration
NA