Fuel Cell Systems Engineer Jobs

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1d ago

Principal Power Electronics Engineer – Fuel Cell Systems

Plug Power Inc. Slingerlands, NY

Slingerlands, NY

1d ago

$114k - $185k/yr Full time Electrical Engineering Design Design Engineering

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Job Description

Plug Power Inc. is seeking a Principal Electrical Engineer to serve as the electrical technical authority for hydrogen fuel cell power systems. This role is based at the company facility in Slingerlands, NY (onsite) and reports to the Manager of Electrical Engineering – Fuel Cell Platforms, leading electrical design, embedded controls, validation, compliance, and cross-functional execution from concept through production release.

What You’ll Do

Architect, design, and validate DC/DC power converters for fuel cell stack and BOP interfaces, including LLC, phase-shift full bridge, interleaved boost, and buck-boost topologies; define specifications for voltage and current profiles, efficiency, ripple, and EMI/EMC across operating conditions.
Lead EMI/EMC mitigation from schematic through PCB layout and full system validation; design high-frequency magnetics for efficiency and manufacturability; own protection architecture and SiC/GaN device selection.
Oversee schematic capture and PCB layout review (Altium preferred), including component selection and DFM; conduct and support hardware design reviews such as PDR and CDR and drive issue resolution through root cause and corrective action.
Own architecture, design, and validation of embedded control systems on DSP/MCU/FPGA platforms, including definition of hardware-software interface requirements.
Define the top-level electrical architecture for the fuel cell power system, including power distribution, harness design, sensor integration, grounding strategy, and isolation/protection schemes.
Define BOP electrical requirements for pumps, fans, valves, heaters, and auxiliary loads; specify thermal subsystem electrical requirements and collaborate with Mechanical and Thermal teams on integrated packaging and thermal management.
Lead compliance and certification work for UL, CE, NFPA 2, SAE, and applicable ISO hydrogen and fuel cell standards; support regulatory approvals; establish and own electrical FMEA and functional safety analyses.
Define and own the electrical DVP&R, leading DV and PV testing execution including shock, vibration, thermal cycling, freeze-thaw, cold-start, and accelerated stress and durability testing to identify failure modes and predict system lifespan.
Drive structured root cause and corrective action processes using 8D and DMAIC; maintain and update DFMEA throughout development to mitigate risks prior to production release.
Partner with Supply Chain early to address preferred suppliers, lead time, cost targets, and second-source availability; support supplier qualification and technical reviews.
Implement DFM/DFT practices with Operations and Manufacturing Engineering to resolve assembly, test, and yield issues during pilot build and production launch.
Close the field reliability loop by translating warranty and field failure data into design improvements.
Execute electrical development within Plug Power’s stage-gate process, owning milestones from Concept Freeze through Production Release; lead NPI programs and platform upgrades with TRL and risk tracking.
Represent electrical engineering status and trade-off analysis during cross-functional program reviews, gate reviews, and executive briefings, prioritizing engineering investments across performance, cost, and time-to-market.
Mentor junior and mid-level electrical engineers, supporting continuous improvement in design and verification processes.
Represent Plug Power professionally in all interactions, and perform other assigned duties.

Required Qualifications

Bachelor’s degree in Electrical Engineering or a closely related field; Master’s degree preferred.
10+ years of power electronics development experience in regulated or high-reliability industries (energy, industrial, automotive, or aerospace).
Proven expertise in DC/DC converter design and validation, including topology selection, magnetics design, thermal analysis, and EMC.
Hands-on embedded controls hardware experience on DSP/MCU/FPGA platforms and digital control implementation.
Strong system-level electrical architecture experience in power distribution, protection, grounding, harnesses, and sensor integration; proficiency in Altium (preferred) and circuit simulation tools such as SPICE and MATLAB/Simulink (or equivalent).
Experience developing and executing electrical DVP&R, DFMEA, and DV/PV testing methodologies, including gate review processes.
Experience with electrical compliance and certification for UL, CE, ISO, SAE, NFPA 2 and structured development frameworks (Stage-Gate, DFSS, or equivalent), with familiarity with functional safety standards (ISO 26262, IEC 61508), model-based development, and HIL testing environments.
Direct experience with PEM fuel cell systems, hydrogen energy systems, or electrochemical power systems; SiC/GaN wide-bandgap power device design and application experience is a strong plus.
Experience working directly with Supply Chain on sourcing, supplier qualification, DFM, and end-of-line test strategy development for production launches.
Excellent communication skills, including presenting electrical trade-offs to cross-functional, executive, and customer audiences; ability to travel up to 10%.

Technologies

DC/DC power converters: LLC, phase-shift full bridge, interleaved boost, buck-boost
DSP, MCU, FPGA, SiC, GaN
Altium, SPICE, MATLAB/Simulink, ECAD
8D, DMAIC, DFMEA, DVP&R, HIL testing environments

Benefits

Health, Dental & Vision Insurance eligibility starting from the first day of hire
401(k) with 5% company match
Bonus eligibility
Paid time off including vacation, personal and sick time
Paid Holidays
Wellness Reimbursement Program
Potential to apply for Tuition Reimbursement
Employee Referral program
Employee Assistance Program

Location: Onsite at the facility in Slingerlands, NY
Status: Exempt (salaried)
Department: Fuel Cell Platforms – Electrical Engineering
Travel: Ability to travel up to 10%
Salary: $114,000 - $185,250 per year
Pay rate: $114,000.00 - $185,250.00

Exempt employees are expected to work as many hours as necessary to complete job responsibilities, which may require working more than eight hours a day and more than five days or 40 hours per week.

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