Staff PCB Design Engineer

Job Title: Staff PCB Design Engineer - Power Electronics - Merrimack, NH; or Waukesha, WI (onsite)

Job Description:

Trystar is at the forefront of advancing power solutions, charged and driven by a committed, dynamic team, tackling complex challenges, and creating innovative solutions. Safety and integrity aren’t just buzzwords. They are the North Star guiding us as we aspire to wow our customers every day. We’ve created power solutions that are not only durable and unique but are also the result of serious teamwork from every corner of our organization. Individually and collectively, every team member at Trystar plays for each other and strives to deliver unmatched value and 100% accuracy to our customers every single day.

As a big name and pioneer in power solutions, we’re not just part of the power conversation - we’re shaping its future, and we’re doing so across diverse industry sectors including healthcare, data centers, entertainment, education, government, and commercial construction - just to name a few! We’re committed to growing and evolving our product lineup to stay on top of the game and that includes leaning into sustainable, resilient, and renewable energy solutions.

Our cutting-edge headquarters in Faribault, MN, is partially solar- and wind-powered by our own microgrid! You’ll find that we’re also pushing boundaries across the country at our additional facilities in Troy, MI; Houston, TX; Merrimack, NH; Burnsville, MN; Murfreesboro, TN; Waukesha, WI; Charlotte, NC; Loveland, CO; Mayfield, KY; Seattle, WA; Victoria and Montreal, Canada. Together, we are Trystar, where we power the future and nurture innovation for a brighter tomorrow.

Trystar’s team members are our most important asset, we are in search of a Staff PCB Design Engineer - Power Electronics to join our innovative engineering team at our Merrimack, NH; or Waukesha, WI; sites, this is an on-site position. As a key contributor, you will lead PCB design and layout for complex power conversion and control electronics used in high-power, high-voltage systems. Working closely with electrical, mechanical, firmware, manufacturing, and compliance engineers, you will translate electrical and mechanical requirements into robust, manufacturable PCB assemblies from concept through to production release. Your expertise in mixed-signal, high-voltage, high-current, high-speed, and high-frequency layout will be critical to successful product development. At the Staff level, you will also lead PCB design reviews, mentor other designers and engineers, and help establish PCB standards, libraries, documentation, and design practices across the organization.

We are looking for people who believe in our guiding principles and values of:

• Safety - We believe everyone should leave Trystar facilities in the same or better condition than when they arrived.
• Integrity - We’re honest, transparent, and committed to doing what’s right.
• Customer focus - We have relentless focus on our customers and their success.
• Right with speed - We use good judgement, make thoughtful decisions quickly, and execute them with purpose and intensity.
• Play for each other - We’re a team. We show up for each other and we know that through teamwork we achieve greatness.
• Champion change - We know adaptation and improvement are requirements to survive and to thrive.
• Enjoy the journey - We create an environment where our team feels appreciated and has fun along the way.

In this role you will get to:

• Lead PCB placement and routing for complex power electronics including gate-driver, control, sensing, communications, customer I/O, power-interface, and test assemblies.

• Own PCB designs from floorplanning stackup definition through layout, design review, fabrication documentation, and production release.

• Develop PCB layouts for high-voltage and high-current power conversion systems up to approximately 2000 VDC / 600 VAC, including PCB current paths exceeding 100 A, high-current terminals, and PCB-to-busbar interfaces.

• Apply appropriate creepage, clearance, insulation coordination, grounding, isolation, thermal, EMI/EMC, signal-integrity, and power-integrity design practices.

• Define stackups, controlled impedance, routing constraints, copper requirements, via structures, and other PCB fabrication requirements.

• Collaborate with electrical and mechanical engineers on schematic implementation, PCB floorplanning, packaging, thermal interfaces, connector placement, and ECAD/MCAD integration.

• Work with PCB fabricators and contract manufacturers to resolve DFM/DFA, testability, serviceability, fabrication, assembly, prototype, and production issues.

• Create and maintain footprints, padstacks, mechanical symbols, constraints, PCB standards, and library content; lead PCB design reviews and mentor other designers and engineers.

• Support environmental and regulatory requirements including conformal coating, pollution degree, temperature/humidity considerations, and applicable UL, IEC, IEEE, and IPC requirements.

• Design PCB-based engineering and manufacturing test hardware including interface boards, automated test boards, programming fixtures, and functional test fixtures.

Job Requirements:

BASIC QUALIFICATIONS

• Bachelor’s degree in Electrical/Electronics Engineering, Engineering Technology, or related field with 7+ years of relevant PCB design experience, or equivalent education and directly applicable experience.
• Extensive experience with complex PCB layout using Cadence Allegro PCB Editor / OrCAD or comparable professional ECAD tools.
• Demonstrated ability to take complex PCB designs from schematic and mechanical requirements through production-ready fabrication and assembly documentation.
• Experience designing mixed high-voltage, high-current, analog, digital, and high-speed PCB assemblies, including switching power electronics and 100+ A PCB current paths.
• Strong understanding of PCB fabrication and assembly including stackups, copper weights, controlled impedance, vias, materials, surface finishes, tolerances, and manufacturing capabilities.
• Strong knowledge of creepage, clearance, isolation, grounding, EMI/EMC, thermal management, return paths, differential routing, and other signal/power-integrity fundamentals.
• Experience developing PCB libraries and working with electrical engineers, mechanical engineers, PCB fabricators, and contract manufacturers throughout the product lifecycle.
• Working knowledge of applicable IPC standards and PCB requirements supporting product safety and regulatory compliance.
• Ability to lead PCB design reviews, identify implementation risks, communicate technical concerns clearly, and mentor less-experienced designers and engineers.

ADDITIONAL QUALIFICATIONS

• Experience with OrCAD Capture or similar schematic tools, including schematic review, modification, and implementation of minor circuit changes.
• Experience with SolidWorks or comparable MCAD tools, including ECAD/MCAD collaboration and basic modification of PCB models, board outlines, brackets, enclosures, or fixtures.
• Experience designing PCBs for inverters, motor drives, energy storage systems, UPS systems, or similar high-power equipment, including SiC MOSFET and/or IGBT gate-drive layouts.
• Experience designing manufacturing and automated test hardware, including test PCBs, interface boards, programming fixtures, bed-of-nails fixtures, or functional test systems.
• Experience specifying PCB requirements for conformal coating and harsh environments, including coating keepouts, masking, material compatibility, inspection, temperature, humidity, contamination, and vibration.
• Familiarity with specialized PCB technologies, including thick-copper, high-layer-count, and immersion-cooled PCB assemblies.
• Familiarity with applicable standards such as UL 1741 / UL 1741 SB, IEEE 1547 / 1547.1, UL 840, IEC 60664-1, and relevant IPC design, fabrication, assembly, and conformal-coating standards.
• Experience with PLM, engineering change control, controlled product release, ECAD library administration, or PCB signal/power-integrity analysis tools.
• IPC CID/CID+ certification and experience supporting UL, IEC, FCC, or EMC compliance testing are a plus.
• Position may require occasional travel within North America.