Printed Circuit Board (PCB) Layout Engineer - Power Electronics

PCB Layout Engineer

Role Summary  (P17)

The PCB Layout Engineer is responsible for designing multi-layer PCB layouts for power electronics hardware such as AC-DC rectifiers, DC-DC converters, inverters, onboard/offboard chargers, SMPS, gate drivers, and control boards.

The role focuses on high-power, high-voltage, high-frequency layout, ensuring thermal performance, EMI/EMC compliance, safety isolation, and manufacturability.

Key Responsibilities

1. PCB Layout Design (High Voltage / High Current / High Frequency)

• Design multi-layer PCBs (2–12+ layers) for:
  – Power stages (MOSFET/IGBT/SiC/GaN)
  – Gate driver boards
  – HV/LV sensing circuits
  – Digital controller boards (MCU/DSP)
  – Auxiliary power supplies
• Optimize layout for:
  – Low loop inductance
  – Controlled impedance traces
  – Creepage & clearance for HV designs
  – Short gate loops and Kelvin source routing
  – High current copper thickness and pours

2. EMI/EMC-Optimized Layout

• Apply best practices for:
  – Minimizing switching noise
  – Grounding strategy (AGND/DGND/PGND separation)
  – Shielding and filtering
  – Common-mode noise control
  – Differential pair routing (CAN, LVDS, Ethernet)

3. Thermal & Mechanical Considerations

• Design layouts supporting:
  – Heat spreading
  – Thermal relief, thermal vias
  – Heatsink and busbar interface
  – Component derating and spacing

-- component supports & PCB mounting considering vibration/shock

• Work with mechanical team for 3D integration.

4. Compliance & Safety Layout

• Ensure PCB meets:
  – Creepage/clearance per IEC/UL standards
  – Insulation requirements for HV (>800 Vdc)
  – Automotive or industrial safety rules
• Design as per IPC/IEC standards
• Design isolation barriers with proper spacing and cut-outs.

5. Design for Manufacturability (DFM) & Assembly (DFA)

• Apply DFM/DFA rules with PCB fabs and assemblers.
• Prepare fabrication files  Gerber/ODB++, Drill files, Stack-up,  Mask files, Assembly drawings, Pick & place data
• Generate 3D models of the PCB
• Perform /coordinate Signal integrity and Power Integrity Analysis

6. Library & Documentation Management

• Create and maintain symbols, footprints, and 3D models.
• Maintain layout documentation, revision control, and release notes.

7. Cross-Functional Collaboration

• Work with:
  – Power Electronics/ Hardware circuit designers
  – Embedded/control engineers
  – Mechanical engineers
  – Manufacturing and quality teams
• Participate in design reviews (DR0/DR1/DR2/DFM review).

Required Skills & Qualifications

Technical Skills

• Strong experience in PCB layout for power electronics converters.
• Experience in layout of Control boards with DSP/microcontrollers/FPGA
• Expertise in:
  – High-voltage (400V, 800V, 1500V)
  – High-current (>100A)
  – High-frequency SiC/GaN switching layouts
• Knowledge of EMI/EMC and grounding rules.
• Strong understanding of analog, digital, and mixed-signal routing.
• Understanding of PCB manufacturing constraints, soldering and assembly process
• Good understanding of IPE /IEC standards for PCB layout (IPC2220series, IPC7531 etc)

Ability to read schematics and understand converter topologies.

Tools

• Cadence Allegro / OrCAD
• Altium Designer 
• Mentor Graphics (PADS/Xpedition)
• ECAD-MCAD integration (SolidWorks/Creo)

Experience

• PCB layout experience in AC-DC PFC, LLC/DC-DC converters, Inverters/traction converters, EV chargers / BESS modules and their controllers
• Experience with wide-bandgap SiC/MOSFET modules is an advantage.

Qualifications

• B.E / B.Tech in Electronics, Electrical, Mechatronics.
• Experience Levels    4–10 years with 5+ years in PCB layout
  
  

Preferred Experience

• Circuit Design experience.
• Hands-on knowledge of Kelvin source routing, Snubber loop optimization, Gate driver–power stage co-layout
• Knowledge of simulation tools (ANSYS SIwave, HyperLynx) preferred.
• Familiarity with safety standards (UL, IEC 61800, IEC 61000).