Prototype Development Engineer

As a Prototype Development Engineer, you will be the bridge between conceptual design and physical reality. You will support the bring-up, integration, and maintenance of critical test assets, including advanced Labcars and prototype vehicles. This is a high-impact role where you will collaborate with cross-functional engineering teams and technicians to ensure our next-generation electric vehicle (EV) architectures are validated and ready for the future of mobility. You won't just be maintaining hardware; you will be driving the launch of Ford’s most ambitious vehicle platforms.
What You’ll Do
• Asset Bring-Up: Support the development and commissioning of Labcars, HIL (Hardware-in-the-Loop) benches, and prototype vehicles.
• Technical Execution: Perform and oversee component installation, complex wiring, module software flashing, and network debugging (CAN, LIN, Automotive Ethernet).
• System Diagnostics: Troubleshoot and triage complex electrical and software integration issues, utilizing deep-dive analysis to resolve roadblocks during build events.
• Strategic Testing & Validation: Develop comprehensive test strategies to validate full-system functionality; perform rigorous regression testing to ensure system stability and performance consistency across multiple hardware and software iterations.
• Cross-Functional Collaboration: Interface with Systems Integration teams to identify design changes between build phases and support iterative development cycles.
• Field Support: Provide hands-on support during prototype build events, fleet management activities, and off-site testing (requires travel).
• Documentation: Maintain rigorous records of module status, hardware revisions, and integration maturity to provide clear visibility to stakeholders.
• Test Asset Design Support: Contribute to the design and development of test assets by leveraging CAD tools and cross-discipline (ME + EE) knowledge to support both electrical and mechanical validation needs.

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or recruiting process, please send a request to HR@insightglobal.com.To learn more about how we collect, keep, and process your private information, please review Insight Global's Workforce Privacy Policy: https://insightglobal.com/workforce-privacy-policy/.

REQUIRED SKILLS AND EXPERIENCE
• Education: Bachelor’s Degree in Electrical, Mechanical, Computer, or Software Engineering.
• Experience: 5+ years of hands-on experience in hardware-software integration, board bring-up, or vehicle systems engineering.
• Network Expertise: 5+ years of experience with vehicle communication protocols, specifically CAN, LIN, and Automotive Ethernet.
• Tooling: 3+ years of experience using embedded networking interface tools (e.g., CANalyzer, CANoe, Wireshark, VSPY3, or similar).
• Technical Skills:
o Proficiency in reading and interpreting complex electrical schematics and PCB assemblies.
o Experience writing and executing formal test plans with clear go/no-go criteria.
o Strong understanding of Embedded Systems fundamentals.
• CAD & Test Engineering: Experience with CAD authoring tools and hands-on automotive EE testing, with the ability to support the design (both mechanical and electrical) of test assets.
• Travel: Ability to travel 25%-75% to support vehicle builds and off-site testing.

• Advanced Knowledge: Advanced vehicle architecture.
• Specialized EV Experience: Working knowledge of battery management systems (BMS), motor calibration, OBD diagnostics, and functional safety (ISO 26262).
• Data Acquisition: Experience instrumenting sensor systems and using DAQ tools for high-fidelity data analysis.
• Prototype Development & Technical Skills: Hands-on support in prototype development, including CAD (CATIA or similar), PCB design (Altium or similar), HV/LV test asset design, harness fabrication and debugging, scripting (Python or similar), and test automation.

Benefit packages for this role will start on the 1st day of employment and include medical, dental, and vision insurance, as well as HSA, FSA, and DCFSA account options, and 401k retirement account access with employer matching. Employees in this role are also entitled to paid sick leave and/or other paid time off as provided by applicable law.