Hardware Validation Systems Developer

About the Role

Heron Power is a startup building cutting-edge power electronics for the 21st-century grid. We aim to de-bottleneck the growth of electricity generation and consumption with scalable, innovative, and less costly hardware solutions, accelerating the electrification of everything. Our first goal is to build better converters (inverters & rectifiers) to connect large-scale renewables, storage, and loads to the grid.

Heron’s leadership team comprises seasoned veterans who have designed and shipped gigawatts of power conversion products over the past decade. We foster a collaborative, enriching environment conducive to personal, technical, and career growth. You can expect to work in a dynamic environment driven by first-principles engineering, solving difficult problems with a strong bias toward hands-on execution and learning by doing.

As the Hardware Validation Systems Developer, you will build the automated hardware test infrastructure that allows us to validate and ship at scale—from PCBA-level functional circuit testing through subsystem validation, end-of-line system testing, and high-volume manufacturing of low-voltage electronics and high-power converter assemblies. This role owns the lifecycle loop from test requirements to coverage strategy, test architecture, fixture/bench design, automation software, deployment, sustainment, regression, and continuous improvement.

Responsibilities

• Test Strategy & Architecture (PCBA → System → EOL)
  • Define functional test coverage for PCBAs, subsystems, and full systems.
  • Architect test solutions balancing coverage, cycle time, cost, and maintainability.
  • Partner with design engineering to drive Design-for-Test (DFT): test points, boundary scan, firmware testing, and observability.
  • Define regression strategy to prevent re-learning lessons across builds and firmware releases.
  • Establish pass/fail criteria grounded in real system performance and reliability goals.
• High-Power / High-Voltage Bi-Directional Converter Testers
  • Design and deliver automated bi-directional converter testers for AC/DC and DC/DC systems capable of source and sink operation.
  • Architect high-power test cells including bidirectional AC/DC sources, regenerative loads, grid simulators, HV measurement chains, contactors, protection systems, interlocks, and safe operating procedures.
  • Implement automated test sequences for power cycling, efficiency mapping, transient response, fault injection, and protection validation.
  • Ensure high-voltage testing is safe, repeatable, and production-ready.
• Test Hardware & Fixture Development
  • Design and build PCBA functional fixtures (bed-of-nails, pogo, interface boards), harness and connector validation fixtures, subsystem and system-level interface racks, and fault-injection rigs.
  • Specify and integrate instrumentation including power supplies, electronic loads, DAQs, DMMs, oscilloscopes, power analyzers, CAN/Ethernet/RS-485 tools, and sensors.
  • Deliver stations that are robust, safe, maintainable, and scalable.
• Debug, Yield & Continuous Improvement
  • Drive rapid debug loops when tests fail and improve test observability and diagnostic resolution.
  • Own station version control, calibration, uptime, and software releases.
  • Partner with manufacturing to improve yield, reduce escapes, and accelerate learning loops.
  • Close the loop with design and reliability teams.

What Makes This Role Different: You will build the automated tester capability from the ground up, covering PCBA functional testing, engineering validation, high-power HIL, end-of-line testing, and production. This role offers high agency and direct ownership of high-voltage, high-energy automated test systems, determining how fast we can iterate and ship.

Requirements

• Must-Have Requirements
  • Bachelor’s degree in Electrical Engineering, Computer Engineering, Mechatronics, or equivalent practical experience.
  • Experience designing and delivering automated test setups for high-voltage / high-power systems.
  • Strong fundamentals in circuits and instrumentation.
  • Hands-on experience with scopes, DMMs, power supplies, electronic loads, DAQs, and digital interfaces (CAN, Ethernet, SPI, I2C, UART).
  • Demonstrated ownership of a test system from concept through deployment and sustainment.
  • Ability to work cross-functionally and drive issues to closure.
• Nice-to-Haves
  • Experience with bi-directional AC/DC or DC/DC power sources and regenerative loads.
  • Experience with HIL development or embedded firmware validation infrastructure.
  • Experience with PCBA manufacturing functional test and yield improvement.
  • Familiarity with production traceability systems and calibration discipline.
  • Experience developing test systems for medium-voltage or high-power converter products.

Pay

Heron Power provides competitive compensation (salary and equity). The salary for this role ranges from $130,000 to $189,000 per year.