HV Safety Mechanical \u0026 Integration- Core Engineering

The High Voltage Safety Integration (HVSI) Team is part of the Global Power Electronics Engineering organization and serves as the technical core team for HV safety compliance, mechanical integration compliance, and DC bus integration compliance across all power electronic devices not limited to Inverters, On board chargers, and DC‑DC Converters and relevant power electronics component. The team collaborates closely with global power electronics engineering groups, vehicle architecture teams, and suppliers to ensure that HV components are safely packaged, compliant with regulations, and fully integrated into the vehicle environment. The High Voltage Safety Integration Engineer ensures that all electrified vehicle programs meet global safety regulations through robust crash‑avoidance design, compliant HV packaging for all HV components, and cross‑functional technical integration.

Core Responsibilities:

• Ensure high‑voltage (HV) safety compliance across all electrified vehicle programs through robust design execution, packaging strategies, and crash‑avoidance solutions.
• Lead technical assessment of CAE crash simulations, physical crash test results, and supplier analyses to identify safety risks and drive continuous design improvement.
• Own HV safety and compliance content within the Product Book, ensuring accuracy, completeness, and on‑time delivery in alignment with program milestones.
• Develop, maintain, and communicate the HV Safety Scorecard for leadership and program reviews, providing clear technical recommendations and program status.
• Drive cross‑functional alignment with Powertrain COE, HV Safety Subsystem teams, Crash Safety, and Vehicle Program Teams to ensure timely implementation of safety requirements.
• Ensure compliance with global safety regulations (FMVSS 305, ECE R100) and adherence to GM internal HV safety standards and processes.
• Champion continuous improvement by developing and updating HV safety best practices, lessons learned, and design guidelines across vehicle programs.

Basic Qualifications:

• Bachelors degree in mechanical, Automotive, Aerospace, Electrical Engineering or related degree field

• 5 or more years of experience in product engineering, systems engineering, or vehicle safety development within the automotive industry

• Leading HV safety integration, crash simulation analysis, or crash test correlation activities across multiple vehicle programs

• Working with suppliers to drive design robustness, implement lessons learned, and ensure compliance with safety and packaging requirements

• Hands‑on experience with electrified vehicle architectures (HEV, PHEV, BEV), including HV component packaging and system integration

• Interpreting and applying global safety regulations (FMVSS 305, ECE R100) and internal OEM safety standards

• Familiarity with OEM development processes, program milestones, and cross‑functional engineering workflows

• Strong expertise in CAE crash simulation interpretation, physical crash test analysis, and correlation methodologies.

• Proficiency in reviewing CAD models, GD&T, connectors, vehicle tree structures, and packaging studies for HV safety integration.

• Understanding of DFM, DFA, DFMEA, PFMEA, and design‑for‑service principles.

• Knowledge of power electronics systems not limited to inverters, chargers, MGUs, HV cables and their integration constraints

• Familiarity with PLM systems such as Teamcenter and CAD environments used for vehicle packaging

• Ability to evaluate supplier CAE reports, mold‑flow analyses, and durability assessments; manufacturing knowledge of HV components and castings (HPDC)

• Effective communication and leadership skills to influence cross functional teams and suppliers

• Self‑motivated, detail‑oriented, and committed to delivering high‑quality, safe, and compliant engineering solutions

• Demonstrated ability to mentor and develop junior engineers while contributing to continuous improvement and best‑practice development

• High level of ownership, organization, and accountability while managing multiple vehicle programs and deliverables

Preferred qualifications:

• Masters Degree in Mechanical Engineering
• Crash Safety experience
• Printed Circuit Board (PCB) design and fabrication experience

• Strong expertise in interpretation of CAE crash simulation results, physical crash test data, and CAE‑to‑test correlation methodologies.