PCB Layout Designer in Concord

Drive the future of Formula 1 hybrid technology with GM PPU! We are seeking a skilled PCB Layout Designer to craft high-performance hardware for our Energy Recovery System (ERS) electronics in Concord, NC. In this critical hands-on role, you will specialise in PCB layout, routing, optimisation, simulation, and testing for power electronics like CU-K inverters, DC-DC converters, power distribution modules, sensors, and control interfaces, ensuring they thrive under extreme race conditions while meeting FIA F1 standards.

Key Responsibilities:

• Develop detailed PCB layouts using tools like Altium Designer for ERS components, including high-voltage inverters (CU-K), DC-DC converters, power distribution boards, sensor interfaces, and gate drivers, focusing on signal integrity, thermal management, radiated/conducted emissions, and minimal mass.
• Collaborate with ERS Electronics Lead, power electronics engineers, firmware teams, and mechanical/thermal designers to integrate hardware designs into the hybrid power unit, optimising for efficiency, EMI/EMC compliance, high-voltage safety, and compact packaging.
• Lead a full PCB development process, starting with layout requirements and design rule formatting to symbol and footprint creation, taking that all into complex multi-layer layouts to then generate Gerber templates and other manufacturing files.
• Create layouts with test fixtures and validation in mind using test points and accessible pads for both prototype testing and end of line validation.
• Execute and oversee hardware testing including EMC compliance, thermal cycling, high-voltage stress tests, and dyno validation; debug prototypes, analyse failures via oscilloscopes/spectrum analyzers, and iterate designs for reliability under FIA ERS limits.
• Conduct design reviews, FMEA risk assessments, and ensure adherence to IPC standards, FIA regulations for ERS power limits, and PLM processes in Teamcenter.

Required Qualifications:

• 3+ years in PCB layout, hardware design, and testing for high-reliability power electronics, preferably in motorsport, hybrids, or aerospace.
• Advanced proficiency in Altium Designer (required), experience with high-speed/high-voltage/high-power PCB design, stack-up optimisation, controlled impedance routing, simulation tools (LTSpice), and test equipment (oscilloscopes, spectrum analyzers).
• Strong knowledge of wide-bandgap semiconductors, EMI/EMC mitigation, HV safety protocols, F1 hybrid regulations, and testing methodologies; familiarity with harness integration and automated manufacturing.
• Experience in designing at minimum 4-layer PCB boards, including flexible circuit boards, to minimise EMI, optimise for packaging and mass, and applying IPC standards and practices.
• Familiarity with creating and managing component libraries, creating request pipelines and managing assignments, ranging from passives to complex 100+ pin custom components and their respective footprints.
• Familiarity with electrical simulation software (LT-Spice, PSIM, PLECS) to create simulations and understand power requirements, thermal constraints, and independently choose component sizing.
• Experience routing and laying out power electronics components for high power applications, routing noise sensitive signals such as gate drives and sense lines around semiconductors and magnetics with attention to EMI mitigation and shielding.

Desirable Skills:

• Bachelor's in Electrical/Electronics Engineering or related field.
• Hands-on experience in motorsport PCB prototyping, dyno/track testing, failure analysis, and rapid iteration under tight deadlines.
• Expertise in data-driven optimisation, advanced packaging (e.g., embedded passives), quality frameworks, and test automation for high-pressure environments.
• Proven collaboration in multidisciplinary teams pushing performance limits.

Drive the Future of Motorsport with GM PPU! At GM PPU, we’re not just building power units — we’re shaping the future of Formula 1 technology. Our culture of collaboration fuels creativity and innovation, empowering you to make a real impact on the track. Every idea counts, every breakthrough matters, and every team member contributes to our competitive edge. If you’re passionate about revolutionising electric motor technology and ready to help us push the limits of performance, this is your chance to join a high-energy, cutting-edge team on a mission to dominate the grid. Your journey to F1 starts here! Apply today and become part of something extraordinary.

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.