Senior Magnetics Design Engineer at Exxelia

Job Summary:

Exxelia USA, part of the Exxelia Group and HEICO, is a leading designer and manufacturer of high-reliability passive components and precision subsystems. We are seeking an experienced Senior Magnetics Design Engineer to join our Magnetics Design Center Team. In this role, you will develop electrical designs and mechanical configurations for custom transformers, inductors, filters, and other magnetic components. Your responsibilities will include contributing to the design and specification of custom tooling, assembly fixtures, inspection fixtures, BOMs, and process instructions. As a Senior Magnetics Design Engineer, you will leverage your expertise to enhance Exxelia’s competitive edge in quotations, new product developments, and successful production, while also engaging in the trial and verification of new technologies.

Responsibilities:

• Translate customer magnetics requirements into success criteria and specifications for components and processes.
• Develop and leverage computer aided modeling and simulation methods for design trade-off analyses, including finite element analyses.
• Communicate effectively with customers, suppliers, and team members to support collaborative new product development.
• Analyze experimental results from designs of models and prototypes to recommend improvements and cost reduction strategies.
• Monitor external technology developments related to power electronics and magnetics design tools and advise management on opportunities and risks.
• Participate in daily team huddles to review project statuses and collaborate on overcoming challenges.
•  Develop milestone plans and deadlines for project completion, ensuring accountability and timely updates on progress.
• Establish initial concepts of magnetics solutions in quotations and prototypes, with related manufacturing processes including provision for custom tooling and new special machines, while working with suppliers to create cost-effective designs.
• Propose improvements during production to reduce labor time and enhance safety and process consistency.
• Develop control plans and test circuits for new magnetics products including custom electrical testing involving sinusoidal, resonant, and non-sinusoidal methods to simulate waveforms and amplitudes of application in measuring dissipation, partial discharge or other selected parameters.
• Participate in problem solving sessions involving DFMEA, PFMEA, HALT and PPAP (including MSA & PCP for target factories).
• Support assigned projects, guiding design reviews from prototype through First Article to production, including lifecycle product change control. Collaborate with the Design Center Tiger Team to understand and enhance manufacturing processes for magnetic components, addressing any roadblocks.
• Provide technical support to Exxelia factories by resolving production issues related to manufacturing processes, materials, and inspection.
• Attend weekly training sessions on configuration control, drawing requirements, supplier management, and related engineering processes.
• Complete additional tasks as required to support Exxelia’s objectives.

Qualifications:

• BS degree in Electrical Engineering.

• 5-10 years of experience in designing custom passive magnetic components for demanding power electronics applications and a demonstrated record of successful results.

• Passion for continued professional development in magnetics design methods, materials and processes.

• Proficient in Ansys, Comsol, SolidWorks, and electrical circuit simulation tools (e.g., PSPICE, Matlab-Simulink).

• Strong organizational and communication skills to collaborate effectively with global colleagues and suppliers.

• Ability to coordinate multiple projects and manage time and resources efficiently.

• Must meet eligibility requirements for access to export-controlled data.

Exxelia Micropen is committed to equal opportunity for all, without regard to race, religion, color, national origin, citizenship, sex, sexual orientation, gender identity, age, veteran status, disability, genetic information, or any other protected characteristic.