ERS Electronics Validation Engineer

GM Performance Power Units - Concord, NC

ERS Electronics Validation Engineer - Onsite

Job Summary

GM Performance Power Units is seeking an ERS Electronics Validation Engineer to join our Formula 1 power unit program in Concord, NC. You will own the verification and validation of Energy Recovery System (ERS) electronic hardware, taking it from early prototype through to homologated, race-proven specification. Working closely with design, controls, thermal, and manufacturing teams, you will plan and run the test programs that prove performance, reliability, and regulatory compliance before hardware reaches the track.

Key Responsibilities

Own the validation strategy and DVP test plans for ERS electronic hardware — CU-K inverter power stage, gate drive, DC-DC converters, sensing and control boards, power distribution, contactors, fuses, sensors, and HV harnesses — from requirement to signed-off evidence.

Design, build, and commission test benches and rigs: motor emulators, HV DC supplies and loads, double-pulse test setups, thermal-cycling and shaker fixtures, HV insulation and partial-discharge test stands, and associated safety interlocks and HVIL.

Execute functional, performance, and abuse test campaigns — efficiency and loss mapping, thermal characterization, HV endurance and cycling, vibration and shock, ingress and fluid compatibility, and EMC pre-compliance (conducted and radiated emissions, immunity).

Post-process and interpret high-rate measurement data (Python, MATLAB, Concerto), correlate results against LTspice/PLECS/Simulink and thermal models and quantify measurement uncertainty in every reported result.

Support component, rig, and full power-unit dyno testing, including instrumentation specification, calibration, and on-cell troubleshooting of electronics faults.

Lead failure investigation and root-cause analysis on returned hardware — electrical fault isolation, teardown and inspection coordination, FRACAS entry, and closure of corrective actions into the design.

Contribute to DFMEA and DVP reviews, design gate reviews, and reliability and race-life assessment for ERS electronic assemblies.

Generate the test evidence and documentation required to demonstrate compliance with FIA Formula 1 Technical Regulations for ERS power, safety, and HV requirements, and to support homologation submissions.

Required Qualifications

Bachelor's degree in Electrical Engineering, Electronic Engineering, Power Electronics, or a related discipline with 3+ years of relevant experience, or a Master's/PhD with 1+ years.

Hands-on test and validation experience with power electronics or high-voltage electrical hardware — inverters, converters, battery systems, or equivalent traction-grade assemblies.

Practical laboratory competence with oscilloscopes, current probes, differential probes, power analyzers, HV insulation and hipot testers, data acquisition systems, and environmental chambers.

Working knowledge of high-voltage safety practice: LOTO, HVIL, isolation monitoring, creepage and clearance, and safe working procedures around energized HV equipment.

Ability to read and debug schematics and PCB layouts (Altium preferred) and to fault-find at board and assembly level.

Proficiency in test data post-processing and automation using Python or MATLAB.

Structured approach to test planning, documentation, and traceability, with clear written reporting of results and conclusions.

Willingness to work to a race calendar — intensive test periods, occasional weekends, and rapid turnaround when the program demands it.

Preferred Qualifications

Motorsport experience — F1, WEC LMH/LMDh, IMSA GTP, or Formula E — particularly ERS, inverter, or HV battery validation.

Experience with wide-bandgap (SiC/GaN) power stages, double-pulse testing, and switching loss characterization.

EMC test experience: chamber testing, pre-compliance measurement, grounding and shielding investigation, and CISPR/ISO 11452-style methods.

Familiarity with simulation and correlation tools — LTspice, PLECS, PSIM, Simulink, or thermal FEA — and with model validation against measured data.

HiL and SiL test experience, CAN/CAN-FD and Ethernet bus tooling, and embedded software or FPGA-in-the-loop validation.

Reliability engineering exposure: DFMEA, HALT/HASS, Weibull analysis, accelerated life testing, and FRACAS.

Knowledge of FIA Formula 1 Technical Regulations relating to ERS, HV safety, and homologation.

Experience with dyno or trackside support, rapid prototyping, and IPC workmanship and quality standards.

Why Join Us

Ready to be part of a team that pushes boundaries both on and off the track? At GM Performance Power Units, we are developing a new era of performance for the Formula 1 grid. Joining us means entering a startup racing environment backed by a legacy of engineering excellence, giving you the rare opportunity to help build a world-class program from day one. We believe in rewarding innovation and powering potential. As part of our team, you’ll benefit from a competitive and comprehensive package designed to support your performance, well-being, and future, helping you thrive at every level.

That includes access to:

Bonus scheme

Private healthcare

401(k) plan including company match

Employer-paid life insurance and disability coverage

32 days annual leave (including holidays)

Free financial advisor access

Employee Assistance Programs (EAP)

Subsidized on-site dining

On-site gym

Discounted GM vehicle purchase/lease program

Free on-site EV charging for personal GM vehicles

It’s all part of our commitment to creating a workplace that’s as high-performing and forward-thinking as the people who make it succeed.

Join us and help power what’s next.

You’ll play a pivotal role in ensuring the reliability and performance of a next-generation Formula 1 power unit. Our culture rewards precision, innovation, and the relentless pursuit of performance.

Please note: GM Performance Power Units and all affiliated companies are Equal Opportunity employer(s). Minorities, women, veterans, and individuals with disabilities are encouraged to apply. For more information regarding the EEOC, please visit https://www.eeoc.gov/employers/upload/poster_screen_reader_optimized.pdf.

Only direct hires need apply to or inquire about job postings at GM Performance Power Units. We are not accepting calls, resumes or applications from recruiting firms at this time.