Senior Wire Harness Engineer

Job Summary

As a Senior Wire Harness Engineer, you are a core technical contributor responsible for the "nervous system" of our humanoid platform. You will design, route, and validate the complex wire harnesses that enable Apollo to move, sense, and think. This role requires a strong blend of electrical system knowledge and mechanical integration. You will execute critical power and data distribution designs, ensuring our interconnect systems are robust, manufacturable, and optimized for high reliability in a dynamic electromechanical machine.

ESSENTIAL DUTIES AND RESPONSIBILITIES or KEY ACCOUNTABILITIEs

• Harness Design & Routing: Design, route, and document complex wire harness assemblies, developing detailed 2D/3D drawings, schematics, and full Bills of Materials (BoMs) using enterprise E-CAD software.
• Dynamic Joint Routing: Apply best practices for routing cables across high-DOF (Degree of Freedom) joints. Select wire types, jackets, and shielding materials that survive extreme dynamic environments and high-cycle fatigue.
• Cross-Functional Collaboration: Act as a key technical bridge between Electrical Engineering, Mechanical Engineering, and Manufacturing. Optimize harness placement within tight spaces while balancing connector density, serviceability, and thermal constraints.
• Design for Excellence (DfX): Drive Design for Manufacturability (DfM) and Assembly (DfA) initiatives to reduce harness complexity, part count, and assembly time. Support the integration of advanced techniques like overmolding and custom backshells.
• Testing & Failure Analysis: Conduct root cause analysis on harness and interconnect failures. Participate in DFMEAs and perform hands-on validation (e.g., continuity, Hi-Pot, and pull-force tests) to identify and mitigate hidden failure modes.
• Vendor Support: Work closely with the supply chain team and external harness manufacturing partners to clarify technical requirements, resolve DFM feedback, and ensure quality during the transition from prototype to production.
• E-CAD & Standardization: Maintain clean component libraries and utilize E-CAD workflows effectively. Help enforce drawing standards and documentation best practices.
• Mentorship: Provide technical guidance and support to junior engineers and assembly technicians, fostering a collaborative culture of engineering rigor.

Skills and Requirements

• Subject Matter Expertise: Strong knowledge of High-Speed Data (e.g., GMSL, CAN, Ethernet) and High-Power distribution within a single, space-constrained harness.
• Dynamic Routing: Proven track record of designing high-flex cabling for dynamic applications (robotics, aerospace gimbals, automotive doors, or similar).
• E-CAD Proficiency: Strong proficiency in modern E-CAD software (e.g., Zuken E3.series, Siemens Capital, SolidWorks Electrical, Rapid Harness, or Altium).
• Physics-Based Design: Solid understanding of wire sizing, voltage drop, EMI/EMC shielding principles, signal integrity, and thermal derating in bundled configurations.
• Communication: Excellent problem-solving and communication skills; able to articulate technical trade-offs clearly to cross-functional peers.
• Industry Standards: Direct experience with common industry standards for harness manufacturing and quality control

EDUCATION and/or EXPERIENCE

• Experience: Bachelor's or Master's degree in Electrical Engineering, Mechanical Engineering, or Robotics with 4+ years of experience designing wire harnesses for complex electromechanical systems

Physical Requirements

• Prolonged periods of sitting at a desk and working on a computer
• Must be able to lift 15 pounds at times
• Vision to read printed materials and a computer screen
• Hearing and speech to communicate

*This is a direct hire. Please, no outside Agency solicitations.