Senior Discrete Power Electronics Engineer

Job Description

Job Description

Why Join Aegis Power Systems, Inc.?

Aegis Power Systems, Inc. is a leading designer and manufacturer of ruggedized power electronics supporting defense, aerospace, and industrial applications. Our products power mission-critical systems where reliability, security, and compliance are non-negotiable. 

As part of our continued growth, we are strengthening our quality systems, engineering collaboration, and manufacturing capabilities to ensure our products consistently meet customer, regulatory, and internal standards. You’ll join a stable, hands-on environment where engineering directly impacts real mission outcomes. 

Position Summary

The Senior Discrete Power Electronics Engineer is responsible for the design, development, analysis, and testing of high-reliability power conversion products utilizing discrete power electronic components and custom circuit designs.

This position requires deep understanding of power electronics related to power conversion and power factor correction. The position also requires hands-on expertise in designing power converters at the circuit and component level, including power semiconductor selection, switching topology development, gate-drive circuitry, magnetics, control and feedback circuits, filtering, protection circuitry, and thermal management.

The Senior Discrete Power Electronics Engineer will lead electrical designs from initial requirements and architecture through detailed circuit design, simulation, prototype development, design verification, qualification, troubleshooting, and transition into production. The position will work closely with Engineering, Manufacturing, Quality, Program Management, and customers to develop ruggedized power solutions for demanding defense, aerospace, and high-reliability applications.

Duties and Responsibilities

• Lead the detailed electrical design and development of custom AC-DC, DC-DC, and DC-AC power conversion products utilizing discrete power components and custom circuitry.
• Develop power converter architectures and select appropriate switching topologies based on input/output requirements, efficiency, power density, thermal constraints, reliability, and environmental requirements.
• Design power stages using discrete semiconductor devices, including MOSFETs, IGBTs, GAN, diodes, rectifiers, and other power switching devices.
• Design and analyze gate-drive circuits, protection circuits, current and voltage sensing circuits, feedback networks, snubbers, clamps, filters, and supporting analog circuitry.
• Design, specify, and evaluate magnetic components including transformers, inductors, and common-mode/differential-mode filtering components.
• Perform detailed circuit calculations, simulations, worst-case analysis, component stress analysis, tolerance analysis, and component derating.
• Analyze switching characteristics, losses, efficiency, transient response, stability, and control-loop performance.
• Select discrete electronic components based on electrical performance, switching characteristics, thermal performance, reliability, availability, lifecycle, and environmental requirements.
• Develop readable, accurate, and production-ready electrical schematics.
• Work closely with PCB designers to optimize board layouts for high-current and high-voltage paths, switching loops, grounding, signal integrity, thermal performance, EMI/EMC, creepage and clearance, and manufacturability.
• Develop and maintain complete Bills of Material (BOMs) within the company’s ERP/DBA system.
• Develop thermal-management solutions for discrete power devices, magnetics, and other heat-generating components.
• Perform power-loss and thermal calculations and support the selection of heat sinks, thermal interface materials, airflow requirements, and other cooling solutions.
• Define electrical test requirements, design tolerances, and acceptance criteria for power electronic designs.
• Perform hands-on prototype bring-up, laboratory testing, debugging, and troubleshooting of power conversion circuits.
• Use oscilloscopes, differential probes, current probes, power analyzers, electronic loads, function generators, and other laboratory equipment to evaluate converter performance.
• Perform root-cause analysis of electrical failures and develop corrective design solutions.
• Lead and participate in internal and customer design reviews.
• Support engineering verification, design validation, environmental qualification, EMI/EMC testing, and customer acceptance testing.
• Review and interpret customer specifications and applicable military, aerospace, safety, and regulatory requirements.
• Provide technical support to Manufacturing Engineering and Production during prototype builds, new product introduction, and ongoing production.
• Develop and maintain engineering documentation including design calculations, analysis reports, test procedures, test reports, specifications, drawings, and design-review documentation.
• Mentor junior and mid-level engineers and provide technical guidance related to power electronics design.
• Continuously identify opportunities to improve power density, efficiency, reliability, thermal performance, manufacturability, and cost.

Required Technical Expertise

Strong hands-on knowledge of:

• Discrete power semiconductor circuit design
• MOSFETs, IGBTs, power diodes, rectifiers, and switching devices
• Switching power supply design
• AC-DC, DC-DC, and/or DC-AC conversion
• Power converter topology selection and design
• Hard-switching and soft-switching techniques
• Gate-drive circuit design
• Magnetics design and component selection
• Feedback and control-loop design and stability analysis
• Current and voltage sensing
• Protection circuitry including overcurrent, overvoltage, undervoltage, and thermal protection
• Snubber and clamp circuit design
• Input/output filtering
• EMI/EMC mitigation techniques
• Component derating and worst-case circuit analysis
• Power-loss and efficiency analysis
• Thermal management of power semiconductor devices
• High-voltage/high-current PCB layout considerations
• Prototype bring-up and component-level troubleshooting

Software and Laboratory Tools

Working knowledge of:

• PSpice or equivalent circuit simulation and analysis software
• AutoCAD or equivalent engineering drafting software
• Microsoft Office Suite
• ERP/MRP systems; experience with DBA Manufacturing is preferred
• Oscilloscopes and high-voltage differential probes
• Current probes
• Power analyzers
• Electronic loads
• AC/DC power sources
• Digital multimeters
• Function generators and other electrical laboratory equipment

Preferred Defense & Aerospace Experience

Experience with ruggedized and high-reliability power electronics and familiarity with applicable requirements such as:

• MIL-STD-461 – EMI/EMC
• MIL-STD-810 – Environmental requirements
• MIL-STD-704 – Aircraft electrical power
• MIL-STD-1275 – Military vehicle electrical power
• DO-160 or similar aerospace environmental requirements
• Applicable UL safety requirements
• Component derating and high-reliability design practices
• Environmental and qualification testing
• AS9100 engineering/manufacturing environments

Key Competencies

• Expert-level power electronics design and troubleshooting capability
• Strong understanding of power converter operation at the component level
• Ability to take a power converter from requirements through detailed design, prototype, test, qualification & production
• Strong analytical and problem-solving skills
• Hands-on laboratory and troubleshooting capability
• Ability to independently solve complex electrical design problems
• Strong technical documentation skills
• Effective communication with customers and cross-functional engineering teams
• Ability to provide technical leadership and mentor less-experienced engineers

Minimum:

• Bachelor’s degree in Electrical Engineering from an accredited four-year institution.
• 10+ years of professional electrical/electronic engineering experience.
• Demonstrated experience designing power conversion products using discrete power semiconductor devices & component-level circuitry.
• Strong experience with switching power supply and power converter design.

Preferred:

• Master’s degree in Electrical Engineering with an emphasis in Power Electronics or a related discipline.
• 10+ years of direct power electronics design experience.
• Experience developing high-reliability power conversion products for defense, aerospace, industrial, or other harsh-environment applications.

Compensation & Benefits  

• Competitive Salary + target bonus incentives
• Health, Dental, Vision Insurance 
• HSA & FSA options 
• Life Insurance 
• Voluntary Benefits
• Paid Time Off / Holiday Pay
• Employee Assistance Program 
• Retirement Plan 
• Professional Development Assistance 

U.S. Person Requirement

Due to the nature of Aegis Power Systems’ work and applicable U.S. export control regulations, this position requires the individual to qualify as a U.S. Person as defined by applicable U.S. export control laws and regulations.

Aegis Power Systems is unable to provide employment visa sponsorship for this position.

Work Location

• On-site in Murphy, North Carolina

Equal Employment Opportunity Statement

Aegis Power Systems, Inc. is an Equal Opportunity Employer. We celebrate diversity and are committed to building an inclusive environment for all employees. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.