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Salary: USD 182,500 - 242,500 / annual
Redwood Materials, founded by JB Straubel (Tesla co-founder and former CTO), is North America's largest lithium-ion battery recycler and a leader in second-life battery energy storage systems. The company has deployed the world's largest second-life battery project, delivering power to AI data centers using proprietary in-house engineered energy architecture. Redwood is profitable and positioned to lead a market projected to grow 20–50x over the next decade.
The Staff Power Electronics Engineer will design and develop power conversion systems for next-generation Battery Energy Storage Systems (BESS) serving utility-scale and data center applications. This is a fully on-site role at 100 Hooper, San Francisco, requiring independent ownership of complex circuit- and system-level problems spanning converter topology selection, power-stage component selection, magnetics design, PCB/PCBA layout, thermal analysis, and validation.
Key responsibilities include:
- Design high-voltage (800V–25kVdc, 480–800Vac) and high-power (10kW–500kW) converters for utility-scale BESS and industrial infrastructure
- Conduct comprehensive topology comparison and trade-off analyses evaluating efficiency, power density, cost, and manufacturability
- Perform power-stage component sizing and Si/SiC MOSFET selection based on loss modeling and thermal management
- Design robust gate driver circuits and dedicated gate driver power supplies for safe, high-frequency switching
- Lead design, modeling, and specification of custom magnetic components (transformers, inductors) using Litz-wire or PCB-winding architectures
- Architect low-voltage subsystems including auxiliary power supplies, sensing circuitry, and hardware-level protection
- Design and optimize EMI filters (differential-mode and common-mode inductors, X/Y-caps, damping elements)
- Drive high-voltage, high-power PCB/PCBA layout design ensuring clearance/creepage rules and signal integrity
- Collaborate with cross-functional teams (Mechanical, Controls/Firmware, Supply Chain, Manufacturing, Compliance) to define requirements, test specifications, and achieve industry certifications
The role requires sound engineering judgment, hands-on lab validation skills, and the ability to resolve ambiguous technical trade-offs with limited direction. Success depends on rapid prototyping, hardware iteration, and mentoring test technicians through design verification.
REQUIREMENTS:
- MS or PhD in Electrical Engineering with focus on power electronics
- 5–7 years of electrical engineering experience with strong focus on power conversion or energy storage products for mass production
- Hands-on experience in high-voltage hardware design (up to 1.5kVdc and 800Vac minimum; experience up to 25kVdc and 34.5kVac for solid-state transformers is a plus)
- Experience with power semiconductor selection, gate drive design, and hardware protection circuits
- Deep understanding of power electronics topologies and fundamentals (AC/DC, DC/DC)
- Proficiency with circuit simulation, FEA simulation, and CAD tools (Simulink, LTspice, Ansys Maxwell/Q3D, Altium Designer)
- Demonstrated ability to perform detailed layout of high-power, noise-sensitive PCBs in Altium or equivalent
- Proficiency with lab equipment (oscilloscopes, impedance analyzers, network analyzers, signal generators)
- Foundational knowledge of control theory and embedded systems
- Strong analytical and systematic problem-solving skills
- Proven track record of rapid prototyping and hardware iterations based on cross-functional and supplier feedback
- Strong ability to select circuit components considering both electrical performance and manufacturability (DFM)
- Experience mentoring test technicians to execute design verification, interpret test data, and define component maturity criteria
- Excellent written and verbal communication skills for cross-functional collaboration
