Senior Power Supply and Distribution Design Engineer - Research & Development Engineering

Position Overview:

Eaton’s Aerospace Division is seeking a Senior Power Supply and Distribution Design Engineer to develop advanced power-conversion, inverters and high-voltage electrical-distribution solutions for aerospace and military applications. This senior individual-contributor role will lead assigned designs from requirements and architecture through detailed design, analysis, verification, qualification support, production transition and sustaining.

The position will focus on high-density, high-efficiency DC/DC and AC/DC conversion, DC/AC inversion, power-factor correction, and high-voltage distribution using advanced analog and digital control technologies. The engineer will also support existing products and product derivatives by improving performance, reducing product and manufacturing costs, resolving technical issues, and strengthening quality and reliability.

The successful candidate will collaborate with systems, embedded software, ucontroller and/or FPGA, mechanical, thermal, PCB, test, manufacturing, quality, supply-chain, and program-management teams. This role supports Eaton Aerospace’s electrification strategy and continued growth in Aerospace/Military  electric aircraft and vehicle including eVTOL/eCTOL applications.

What you’ll do:

In This Role You Will
•  Lead assigned power-conversion and power-distribution designs from requirements and architecture through detailed design, analysis, design review, verification, qualification support, and production transition.
•  Translate customer and system-level requirements into electrical, control, protection, thermal, mechanical-interface, reliability, and verification requirements.
•  Develop reliable, cost-effective, manufacturable solutions that meet customer requirements and applicable aerospace, military, regulatory, and product-safety standards.
•  Perform topology and architecture trade studies that balance efficiency, power density, thermal performance, EMI, reliability, cost, schedule, manufacturability, and supply-chain risk.
•  Design switch-mode DC/DC and AC/DC converters, DC/AC inverters, power-factor-correction stages, protection circuits, sensing interfaces, communication interfaces, and high-voltage distribution assemblies.
•  Develop, implement, and validate digital-control algorithms for power-conversion systems using microcontrollers, DSPs, FPGAs, or similar control platforms.
•  Perform loss and efficiency modeling, control-loop stability analysis, worst-case circuit analysis, tolerance and Monte Carlo analysis, component derating, magnetics design, EMI-filter assessment, and thermal analysis.
•  Evaluate component selections considering electrical performance, reliability, cost, availability, lifecycle status, second-source strategy, and supply-chain risk.
•  Develop schematics, design calculations, simulations, interface definitions, design-review packages, verification plans, test procedures, and technical reports.
•  Lead or support architecture, schematic, PCB-layout, design, test-readiness, qualification-readiness, and production-readiness reviews.
•  Plan and execute prototype bring-up, troubleshooting, characterization, and design verification using appropriate power-electronics laboratory instrumentation and safe high-voltage test practices.
•  Analyze test results, identify root causes, implement corrective actions, and document objective evidence of design compliance.
•  Collaborate with PCB, mechanical, and thermal engineers to establish layout, grounding, isolation, packaging, cooling, structural, creepage, clearance, thermal, and EMI requirements.
•  Partner with manufacturing, quality, test, and supply-chain teams to ensure designs are manufacturable, testable, reliable, cost-effective, and ready for production.
•  Support configuration control, engineering changes, product derivatives, component obsolescence, alternate-source qualification, and sustaining-design improvements.
•  Provide technical leadership through design reviews, mentoring, technical decision-making, problem resolution, and development of reusable design practices without direct people-management responsibility.
•  Apply Design for Six Sigma methods, engineering simulation and modeling tools, and phase-gate development processes.
•  Conduct technology and competitive assessments to inform product architectures, component selections, technical roadmaps, and make-versus-buy decisions.
•  Support technical papers, invention disclosures, patents, and technical presentations when appropriate.

Additional Information:

Expected Outcomes
•  Deliver robust power-electronics solutions that meet program technical, cost, quality, and schedule objectives.
•  Meet program-specific efficiency, power-density, thermal, EMI, reliability, and manufacturability requirements.
•  Identify technical risks early and drive disciplined closure of design and verification issues.
•  Maintain complete and traceable design evidence for technical reviews, verification, qualification, and production transition.
•  Improve design reuse and reduce avoidable redesign, test escapes, product cost, manufacturing cost, and sustaining effort.
•  Communicate technical risks, assumptions, trade-offs, and required decisions clearly and early.

Typical Deliverables
•  Power-conversion and high-voltage distribution architectures
•  System and circuit-level requirements
•  Topology, component, and architecture trade studies
•  Schematics and detailed design calculations
•  Control-loop models and stability analyses
•  Magnetics, EMI, thermal, derating, tolerance, and worst-case analyses
•  PCB design requirements and layout-review records
•  Design-review packages and technical decision records
•  Verification plans, procedures, and reports
•  Qualification-support documentation
•  Released drawings, specifications, bills of material, and design records
•  Root-cause and corrective-action documentation

Qualifications:

Basic (Required) Qualifications
•  Master’s degree or PhD in Electrical Engineering, Power Electronics, or a closely related technical discipline from an accredited institution.
•  Minimum seven years of relevant power-electronics design experience, including demonstrated experience with multiple power-conversion topologies, high-density/high-efficiency designs, analog or digital control, magnetics, EMI, thermal management and use of WBG technology and high power, high frequency magnetics (i.e. planar).
•  Experience developing, implementing, and validating digital-control algorithms for power-conversion systems using microcontrollers, DSPs, FPGAs, or similar control platforms.
•  Experience with analog and digital feedback control, loop compensation, stability analysis, and control-system verification.
•  Experience performing circuit simulation, design analysis, laboratory testing, hardware bring-up, debugging, and verification.
•    Experience with component derating, worst-case circuit analysis, failure-mode analysis, reliability prediction, and environmental qualification
•  Experience developing engineering documentation and supporting formal technical reviews.
•  Ability to collaborate across a matrixed, multidisciplinary, and geographically distributed engineering organization.
•  Must be authorized to work in the United States without company sponsorship now or in the future.

•  This position requires use of information or access to hardware which is subject to the International Traffic in Arms Regulations (ITAR) and hig level security projects.   All applicants must be U.S. Citizens due to Military/ Defense project sensitivity. 

Preferred Qualifications
•  Experience developing multi-kilowatt aerospace and military power-conversion and high-voltage electrical-distribution products.
•  Demonstrated ownership of hardware taken through requirements, detailed design, verification, qualification, production transition, and sustaining support.
•  Experience designing power-conversion hardware using silicon and/or wide-bandgap SiC and GaN devices, including gate-drive design, switching behavior, parasitics, thermal performance, protection, layout, and EMI considerations.
•  Experience with FPGA-based control, microcontroller design, embedded interfaces, and hardware and firmware integration.
•  Knowledge of military and aerospace high-voltage power-distribution systems, including architecture, switching and protection, pre-charge, sensing, thermal management, communications, packaging, and fault management.
•  Experience applying applicable electrical and environmental requirements, including DO-160, MIL-STD-461, and MIL-STD-704.
•  Familiarity with DO-178 and DO-254 development-assurance processes and their impact on hardware/software interfaces.  .
•  Experience with PLECS, MATLAB, Simulink, SPICE-based simulation tools, Altium Designer, and SolidWorks.
•  Experience with requirements-management, product-lifecycle-management, configuration-control, or engineering-change systems.
•  Experience supporting customer technical reviews, certification activities, or qualification testing.
•  Project leadership or technical work-package management experience.

Skills:

Position Criteria
•  Demonstrates strong analytical judgment and structured problem-solving ability.
•  Makes sound engineering decisions using objective evidence, appropriate analysis, and documented technical trade-offs.
•  Works effectively in a matrix environment and influences outcomes without relying on direct authority.
•  Communicates technical risks, assumptions, constraints, and required decisions early and clearly.
•  Balances performance, reliability, safety, manufacturability, cost, schedule, and supply-chain considerations.
•  Manages multiple assignments while maintaining accurate, complete, and configuration-controlled technical deliverables.
•  Leads complex troubleshooting and root-cause investigations through disciplined, data-based methods.
•  Builds productive working relationships across engineering, manufacturing, quality, supply chain, program management, suppliers, and customers.
•  Mentors other engineers and contributes to stronger technical practices, design reuse, and continuous improvement.
•  Demonstrates accountability for commitments and follows technical issues through closure.