Mechanical Test EngineerGlobal Connect Technologies • Palo Alto, CA, United States

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Mechanical Test Engineer

Global Connect Technologies • Palo Alto, CA, United States

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Role Overview

We need three hands-on, mechanically oriented Test Engineers who thrives in our test lab. This role balances :

Logistics layer - coordinating with design counterparts, collecting samples, creating JIRA tickets for technicians, and managing test sample logistics.
Hands-on test engineering - designing, building, and iterating on test setups.
Ownership mindset - treating each setup as if it were their own business, balancing speed, safety, and standardization in a fast-paced environment.

Role Overview

We need a hands-on, mechanically oriented Test Engineer who thrives in the lab. This role balances :

Logistics layer - coordinating with design counterparts, collecting samples, creating JIRA tickets for technicians, and managing test sample logistics.

Hands-on test engineering - designing, building, and iterating on test setups.

Ownership mindset - treating each setup as if it were their own business, balancing speed, safety, and standardization in a fast-paced environment.

Key Responsibilities & Skills

1. Design & Build of Test Fixtures

Architect, model, and assemble frames (e.g. 80 / 20, steel, aluminum, composites) to house power systems, control electronics, and devices under test.

Design and build custom control boxes (e.g. microcontroller / relay / switching boards) to actuate and monitor test logic (for example, cycling chargeport latches).

Create harnessing from control box to devices (wiring, connectors, cable management).

Select and integrate components : power supplies, pumps, sensors, relays, data acquisition modules.

Rapid CAD design (SolidWorks or equivalent) of parts, assemblies, and fixtures.

Develop control scripts (Python preferred) for device actuation, chamber / chiller coordination, power cycling, data logging, error handling, interlock logic.

Decompose build and inspection tasks into JIRA (or equivalent) tickets, assign to technicians, and supervise execution and QA.

2. Mechanical Systems & Thermal / Structural Design

Choose pumps, heat exchangers, motors, actuators (servo, stepper, etc.) appropriate for the thermal, flow, mechanical load of the DUT.

Design structural supports, fixtures, mounting surfaces, force-transmitting links, and vibration isolation, considering stiffness, thermal expansion, alignment tolerances, and safety margins.

Apply GD&T (Geometric Dimensioning & Tolerancing) to ensure fixture elements match tolerances and reduce mismatch / rework.

Fabricate custom parts (machining, cutting, bending, welding) or coordinate with external machine shops when needed.

Understand mechanical stresses, thermal expansion, material selection (e.g. aluminum vs. steel, coefficient of expansion) to preserve alignment under extreme conditions.

Recommend and integrate mechanical stress / load elements (e.g. clamping, thermal cycling effects, flexures) for realistic loading of bus bars, junction boxes, chargeports.

3. Electrical, Instrumentation & Signal Integrity

Interpret datasheets and performance specs of HV components (contactors, shunts, relays, power converters).

Size wiring harnesses (gauge, insulation, derating), design noise mitigation (shielding, twisted pairs, grounding), and design simple circuits (e.g. resistor dummy loads, balancing circuits) to support test logic.

Integrate measurement hardware : NI DAQ systems, thermocouples, RTDs, pressure sensors, accelerometers, current & voltage sensors.

Incorporate HV safety features : interlocks, watchdogs, fault detection, safe sequencing, insulation monitoring, and emergency shutdown paths.

Ensure signal timing, synchronization, sample rate, and data integrity across instrumentation channels.

4. Equipment & Test Facility Integration

Work with environmental chambers : plan safe ramp-down sequences (e.g. humidity first), account for thermal soak and enclosure constraints.

Interface with chillers / cooling systems to integrate temperature setpoints into test profiles and manage coolant circulation.

Use advanced / bi-directional power supplies (grid simulators, programmable sources) with SCPI, CAN, GPIB, Ethernet, LXI or RS-232 protocols.

Manage rack systems : power supplies, controllers, cabling, cooling, harness routing, cable length constraints.

Configure and validate test stands to maintain safety clearance, mechanical access, serviceability, and reliability over long test durations.

5. Reliability & Environmental Testing Expertise

Understand and design for reliability test methods common in EV and power component space :

PTCE (Powered Thermal Cycling Endurance)

HTOE (High Temperature Operating Endurance)

HTHE (High Temperature Humidity Endurance)

IP (Ingress Protection / environmental sealing tests)

Develop or adapt fixtures and setups for these tests (thermal cycling, humidity, load cycling) and interpret resulting data for degradation / failure modes.

Use test data and models to accelerate test times (e.g. using real-world load profiles) while maintaining statistical confidence.

Understand aging, fatigue, electromigration, thermal cycling cracks, insulation breakdown, corrosion or humidity-related degradation patterns as inputs to design feedback.

6. Validation, Calibration & Fixture Quality Assurance

Validate fixtures : check alignment, clearance, actuation, contact integrity, wiring, and signal continuity.

Perform fixture checkout and verification prior to production test runs (probe hits, wire verification, interlock tests).

Maintain calibration schedules for sensors and instrumentation to ensure accuracy over long-term usage.

Monitor fixture drift, failure modes, and redundancy in critical paths (spare sensors, fallback mechanisms).

Design with safety in mind : include grounding kits, proper shielding, and ensure human safety in presence of HV.

Target Industries for Candidates

Automotive (EVs, Tier-1 suppliers in power electronics, HV systems)

Aerospace / defense (environmental test, reliability)

Industrial power systems (HV equipment, grid simulation, power distribution)

Electronics testing labs with fixture design / validation experience

Pre-Screening Questions (with examples of good answers)

Can you describe a time you designed and built a custom test fixture from scratch?

Follow-up : How did you choose pumps, power supplies, sensors, and framing?

Follow-up : How did CAD and scripting factor into your solution?

Good answer : Candidate explains building a fixture using 80 / 20 framing, a relay-controlled PSU with Arduino, custom harnessing, and Python scripting for cycling and logging data.

In an 85°C / 85%RH environmental test, what do you ramp down first before opening the chamber?

Good answer : Humidity first, otherwise condensation risks damaging the samples.

How would you reduce electrical noise in a setup with HV and LV wiring running together?

Good answer : Separate HV and LV harnesses, use twisted pairs, shielding, and proper grounding.

How do you decide what pump, heat exchanger, or motor to use in a thermal or mechanical test setup?

Good answer : Candidate refers to flow / pressure / heat load calculations, safety margins, and equipment specs matched to test needs.

Tell us about your experience with instrumentation (DAQs, thermocouples, accelerometers).

Good answer : Candidate describes specific examples of DAQ integration, sensor calibration, and how they analyzed and communicated results.

Quick Checklist for Recruiters

Must-Have :

Hands-on, comfortable designing AND building test setups

Mechanical + electrical fundamentals (framing, pumps, heat exchangers, wiring)

CAD (SolidWorks preferred)

Python scripting (or similar)

HV safety awareness

Preferred :

Experience with NI DAQs, thermocouples, accelerometers

GD&T knowledge / certification

Familiarity with environmental chambers and liquid cooling

Knowledge of power supply communication protocols (CAN, GPIB, SCPI, etc.)

Reliability testing knowledge : IP, PTCE, HTOE, HTHE

Mindset :

Scrappy, ownership-driven, hands-on

Comfortable balancing speed, safety, and standardization

Thrives in a fast-paced, dynamic lab environment

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