Senior/Staff Electrical Engineer - PCBA Development

Hiring Team: BMS Hardware & Electrical Systems Engineering
Location: Weirton, WV (Onsite strongly preferred; remote work may be considered during the contract period, with relocation required upon conversion)
Start Date: ASAP
Experience: 7+ Years
Employment Type: long term Contract
Interview Process: 2 Technical Rounds

About the Role

Client is seeking an experienced Senior/Staff Electrical Engineer to join its BMS Hardware & Electrical Systems Engineering team in Weirton, West Virginia.

This is a high-impact opportunity for an electrical engineer with strong hands-on experience in Printed Circuit Board Assembly (PCBA) development, embedded hardware, power electronics, and electrical system integration.

The ideal candidate will own the complete PCBA development lifecycle, from requirements definition and component selection to schematic capture, PCB layout oversight, board bring-up, validation, and production release. The role supports critical battery management and electrical systems architecture for Form Energy's next-generation battery platform.

Candidates with backgrounds in battery systems, energy storage, electric vehicles, automotive electronics, industrial controls, or other safety-critical environments are strongly encouraged to apply.

Key Responsibilities1. PCBA Design & Development

• Own the complete PCBA development lifecycle, from concept and requirements definition through production release.

• Develop electrical requirements, block diagrams, system architecture documentation, and detailed design specifications.

• Perform component selection and schematic capture using Altium Designer or equivalent ECAD tools.

• Drive PCB layout development and design reviews, focusing on signal integrity, power integrity, manufacturability, and long-term reliability.

• Collaborate with PCB layout engineers and vendors on Design for Manufacturing (DFM) reviews and design release activities.

• Ensure designs meet performance, safety, reliability, and product requirements.

2. Hardware Bring-Up, Integration & Validation

• Develop hardware bring-up procedures, test plans, and verification strategies.

• Perform board bring-up, debugging, electrical validation, and root cause analysis.

• Troubleshoot hardware issues and provide sustaining engineering support for released designs.

• Prepare engineering documentation, test reports, design decision matrices, and 8D corrective action reports.

• Support verification activities to ensure hardware meets system-level requirements.

3. Power & Control Systems

• Design and support 48V power distribution architectures.

• Develop high-power actuator, fan, and sensor control circuits.

• Design and validate power conversion circuits, including buck converters, LDOs, and power management systems.

• Support data acquisition, sensor interfacing, and embedded control systems.

• Work with motor drivers, gate drivers, high-side drivers, ADCs, DACs, and I/O expanders.

4. Communication Interfaces & Embedded Hardware

• Design and integrate communication interfaces, including 1000BASE-T1 Single Pair Ethernet, CAN-FD, SPI, UART, I2C, isoSPI, and JTAG.

• Work with MCUs, MPUs, Ethernet switches, PHYs, and SOM/SMARC carrier board architectures.

• Support hardware interfaces for embedded firmware and software integration.

• Troubleshoot communication and hardware integration issues across system components.

5. Safety, Reliability & Compliance

• Support electrical hardware development for high-power and potentially hazardous operating environments.

• Apply reliability-focused design methodologies and safety-conscious engineering practices.

• Contribute to compliance activities related to applicable standards, including UL 991, UL 1973, UL 1998, and UL 9540.

• Participate in design reviews, risk assessments, and corrective action activities.

6. Cross-Functional Collaboration

• Work closely with Systems Engineering, Mechanical Engineering, Firmware, Software, Manufacturing, and Test teams.

• Participate in architecture discussions, technical design reviews, and system integration activities.

• Balance development speed, engineering rigor, safety, and reliability in a fast-paced environment.

• Independently drive technical decisions, resolve complex hardware challenges, and communicate engineering trade-offs.

Required Qualifications

• Bachelor's or Master's degree in Electrical Engineering, Computer Engineering, or a related technical discipline.

• 7+ years of relevant electrical engineering experience; candidates with a Master's degree and 5+ years of experience may be considered.

• Strong hands-on experience with Altium Designer or an equivalent ECAD platform.

• Demonstrated ownership of schematic capture and PCBA development.

• Experience with multi-layer PCB designs and hardware development.

• Hands-on experience with board bring-up, debugging, and hardware validation.

• Experience across the full product development lifecycle, from requirements through production release.

• Strong knowledge of power electronics, power distribution, and power management circuits.

• Experience with Ethernet interfaces, preferably 1000BASE-T1, and CAN-FD.

• Practical experience with SPI, UART, I2C, and other embedded communication interfaces.

• Experience with data acquisition systems, control systems, and MCU/MPU-based hardware.

• Background in high-power, industrial, automotive, energy, battery, or other safety-critical applications.

• Familiarity with relevant UL safety and compliance standards.

• Strong troubleshooting, technical documentation, and cross-functional communication skills.

• Ability to work independently and take ownership of complex engineering deliverables.

Preferred Qualifications

• 10+ years of electrical or hardware engineering experience.

• Experience with Battery Energy Storage Systems (BESS).

• Background in EVs, automotive electronics, industrial automation, or power systems.

• Experience with DFMEA and CFMEA.

• Familiarity with PLM tools such as Arena or Teamcenter.

• Experience with JIRA and JAMA.

• Experience designing or integrating SOM/SMARC carrier boards.

• Hands-on PCB layout execution experience beyond design review.

• Experience supporting manufacturing handoff, production release, and sustaining engineering.

Ideal Candidate Profile

The ideal candidate is a hands-on senior hardware engineer who has independently owned complex PCBAs from initial requirements through production release.

Strong candidates will demonstrate practical experience in:

• Embedded hardware and multi-layer PCB design.

• Ethernet-based communication, particularly 1000BASE-T1.

• CAN-FD networks and embedded interfaces.

• 48V power distribution and power electronics.

• Hardware bring-up, debugging, and system-level validation.

• Safety-critical hardware development and engineering documentation.

Candidates from battery technology, BESS, EV, automotive electronics, industrial controls, or embedded power systems environments are particularly well suited for this role.

Interview Process

• Round 1: Electrical Engineering Manager

• Round 2: Staff Electrical Engineer / Technical Lead

Work Location & Availability

• Primary Location: Weirton, West Virginia.

• Onsite work is strongly preferred.

• Remote work may be considered during the contract period, but relocation to the Weirton, WV area is required upon conversion.

• Immediate availability is preferred.

How to Apply

Interested candidates with strong PCBA development, embedded hardware, power electronics, and electrical systems experience are encouraged to apply.

Please share your updated resume highlighting your hands-on PCB design experience, Altium expertise, communication interfaces, power electronics background, and hardware validation experience.

Apply now or message me directly to discuss this opportunity.