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Mechanical Test Engineer

Mechanical Test Engineer

Global Connect TechnologiesPalo Alto, CA, United States
5 days ago
Job type
  • Full-time
Job description

Role Overview

We need three hands-on, mechanically oriented Test Engineers who thrives in our test lab. This role balances :

  • Logistics layer - coordinating with design counterparts, collecting samples, creating JIRA tickets for technicians, and managing test sample logistics.
  • Hands-on test engineering - designing, building, and iterating on test setups.
  • Ownership mindset - treating each setup as if it were their own business, balancing speed, safety, and standardization in a fast-paced environment.

Role Overview

We need a hands-on, mechanically oriented Test Engineer who thrives in the lab. This role balances :

  • Logistics layer - coordinating with design counterparts, collecting samples, creating JIRA tickets for technicians, and managing test sample logistics.
  • Hands-on test engineering - designing, building, and iterating on test setups.
  • Ownership mindset - treating each setup as if it were their own business, balancing speed, safety, and standardization in a fast-paced environment.

    • Key Responsibilities & Skills

    1. Design & Build of Test Fixtures

  • Architect, model, and assemble frames (e.g. 80 / 20, steel, aluminum, composites) to house power systems, control electronics, and devices under test.
  • Design and build custom control boxes (e.g. microcontroller / relay / switching boards) to actuate and monitor test logic (for example, cycling chargeport latches).
  • Create harnessing from control box to devices (wiring, connectors, cable management).
  • Select and integrate components : power supplies, pumps, sensors, relays, data acquisition modules.
  • Rapid CAD design (SolidWorks or equivalent) of parts, assemblies, and fixtures.
  • Develop control scripts (Python preferred) for device actuation, chamber / chiller coordination, power cycling, data logging, error handling, interlock logic.
  • Decompose build and inspection tasks into JIRA (or equivalent) tickets, assign to technicians, and supervise execution and QA.

    • 2. Mechanical Systems & Thermal / Structural Design

  • Choose pumps, heat exchangers, motors, actuators (servo, stepper, etc.) appropriate for the thermal, flow, mechanical load of the DUT.
  • Design structural supports, fixtures, mounting surfaces, force-transmitting links, and vibration isolation, considering stiffness, thermal expansion, alignment tolerances, and safety margins.
  • Apply GD&T (Geometric Dimensioning & Tolerancing) to ensure fixture elements match tolerances and reduce mismatch / rework.
  • Fabricate custom parts (machining, cutting, bending, welding) or coordinate with external machine shops when needed.
  • Understand mechanical stresses, thermal expansion, material selection (e.g. aluminum vs. steel, coefficient of expansion) to preserve alignment under extreme conditions.
  • Recommend and integrate mechanical stress / load elements (e.g. clamping, thermal cycling effects, flexures) for realistic loading of bus bars, junction boxes, chargeports.

    • 3. Electrical, Instrumentation & Signal Integrity

  • Interpret datasheets and performance specs of HV components (contactors, shunts, relays, power converters).
  • Size wiring harnesses (gauge, insulation, derating), design noise mitigation (shielding, twisted pairs, grounding), and design simple circuits (e.g. resistor dummy loads, balancing circuits) to support test logic.
  • Integrate measurement hardware : NI DAQ systems, thermocouples, RTDs, pressure sensors, accelerometers, current & voltage sensors.
  • Incorporate HV safety features : interlocks, watchdogs, fault detection, safe sequencing, insulation monitoring, and emergency shutdown paths.
  • Ensure signal timing, synchronization, sample rate, and data integrity across instrumentation channels.

    • 4. Equipment & Test Facility Integration

  • Work with environmental chambers : plan safe ramp-down sequences (e.g. humidity first), account for thermal soak and enclosure constraints.
  • Interface with chillers / cooling systems to integrate temperature setpoints into test profiles and manage coolant circulation.
  • Use advanced / bi-directional power supplies (grid simulators, programmable sources) with SCPI, CAN, GPIB, Ethernet, LXI or RS-232 protocols.
  • Manage rack systems : power supplies, controllers, cabling, cooling, harness routing, cable length constraints.
  • Configure and validate test stands to maintain safety clearance, mechanical access, serviceability, and reliability over long test durations.

    • 5. Reliability & Environmental Testing Expertise

  • Understand and design for reliability test methods common in EV and power component space :
  • PTCE (Powered Thermal Cycling Endurance)
  • HTOE (High Temperature Operating Endurance)
  • HTHE (High Temperature Humidity Endurance)
  • IP (Ingress Protection / environmental sealing tests)
  • Develop or adapt fixtures and setups for these tests (thermal cycling, humidity, load cycling) and interpret resulting data for degradation / failure modes.
  • Use test data and models to accelerate test times (e.g. using real-world load profiles) while maintaining statistical confidence.
  • Understand aging, fatigue, electromigration, thermal cycling cracks, insulation breakdown, corrosion or humidity-related degradation patterns as inputs to design feedback.

    • 6. Validation, Calibration & Fixture Quality Assurance

  • Validate fixtures : check alignment, clearance, actuation, contact integrity, wiring, and signal continuity.
  • Perform fixture checkout and verification prior to production test runs (probe hits, wire verification, interlock tests).
  • Maintain calibration schedules for sensors and instrumentation to ensure accuracy over long-term usage.
  • Monitor fixture drift, failure modes, and redundancy in critical paths (spare sensors, fallback mechanisms).
  • Design with safety in mind : include grounding kits, proper shielding, and ensure human safety in presence of HV.

    • Target Industries for Candidates

  • Automotive (EVs, Tier-1 suppliers in power electronics, HV systems)
  • Aerospace / defense (environmental test, reliability)
  • Industrial power systems (HV equipment, grid simulation, power distribution)
  • Electronics testing labs with fixture design / validation experience

    • Pre-Screening Questions (with examples of good answers)

  • Can you describe a time you designed and built a custom test fixture from scratch?
  • Follow-up : How did you choose pumps, power supplies, sensors, and framing?
  • Follow-up : How did CAD and scripting factor into your solution?
  • Good answer : Candidate explains building a fixture using 80 / 20 framing, a relay-controlled PSU with Arduino, custom harnessing, and Python scripting for cycling and logging data.
  • In an 85°C / 85%RH environmental test, what do you ramp down first before opening the chamber?
  • Good answer : Humidity first, otherwise condensation risks damaging the samples.
  • How would you reduce electrical noise in a setup with HV and LV wiring running together?
  • Good answer : Separate HV and LV harnesses, use twisted pairs, shielding, and proper grounding.
  • How do you decide what pump, heat exchanger, or motor to use in a thermal or mechanical test setup?
  • Good answer : Candidate refers to flow / pressure / heat load calculations, safety margins, and equipment specs matched to test needs.
  • Tell us about your experience with instrumentation (DAQs, thermocouples, accelerometers).
  • Good answer : Candidate describes specific examples of DAQ integration, sensor calibration, and how they analyzed and communicated results.

    • Quick Checklist for Recruiters

    Must-Have :

  • Hands-on, comfortable designing AND building test setups
  • Mechanical + electrical fundamentals (framing, pumps, heat exchangers, wiring)
  • CAD (SolidWorks preferred)
  • Python scripting (or similar)
  • HV safety awareness

    • Preferred :

  • Experience with NI DAQs, thermocouples, accelerometers
  • GD&T knowledge / certification
  • Familiarity with environmental chambers and liquid cooling
  • Knowledge of power supply communication protocols (CAN, GPIB, SCPI, etc.)
  • Reliability testing knowledge : IP, PTCE, HTOE, HTHE

    • Mindset :

  • Scrappy, ownership-driven, hands-on
  • Comfortable balancing speed, safety, and standardization
  • Thrives in a fast-paced, dynamic lab environment
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    Mechanical Engineer • Palo Alto, CA, United States

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