Senior/Staff Manufacturing Engineer - Advanced Processes

OverviewJoin Heron Power, an innovative startup at the forefront of power electronics, dedicated to revolutionizing the 21st-century energy grid. Our mission is to eliminate barriers to electricity generation and consumption through scalable, innovative, and cost-effective hardware solutions, accelerating the electrification of all aspects of life.Our primar…

Join Our Innovative TeamHeron Power is an emerging leader in developing state-of-the-art power electronics designed to meet the challenges of the 21st-century energy grid. Our mission is to remove barriers to the growth of electricity generation and consumption by providing scalable, innovative, and cost-effective hardware solutions, thereby accelerating the electrification of various sectors.Our initial focus is on enhancing converters (including inverters and rectifiers) that connect large-scale renewable energy sources, energy storage, and electrical loads to the grid. Our leadership team consists of industry veterans who have successfully designed and delivered gigawatts of power conversion technologies over the past decade.At Heron, we believe in the power of collaboration and continuous learning. Our workplace fosters a dynamic environment where team members can grow personally, technically, and in their careers. You will be engaging in a stimulating and cooperative atmosphere, driven by first principles engineering and tackling complex challenges.Your RoleAs a Manufacturing Engineer specializing in Advanced Processes, you will play a pivotal role in developing, testing, and scaling high-volume manufacturing processes for our power electronics assemblies. Your expertise will be central to advancing our complex manufacturing technologies, leading the development of processes and equipment for automation, chemical handling systems for thermal interface materials and fillers, and assembly of plastics and metals.Collaboration will be key as you work closely with product, mechanical, and electrical design teams throughout the design for manufacturing (DFM) process. Your contributions will ensure that both the product and the production lines are resilient and efficient. You will also work hand-in-hand with external suppliers and equipment partners to establish scalable, reliable, and repeatable manufacturing processes and equipment lines from inception through to production ramp-up.Key ResponsibilitiesLead the development of manufacturing lines across various processes and equipment technologies from concept through ramp-up.Develop and scale manufacturing processes for thermal interface materials, gap fillers, and dispensing systems.Establish surface treatment processes for plastics and metals, including plasma treatment and chemical cleaning.Specify and qualify advanced joining techniques such as ultrasonic welding and laser welding.Continuously refine processes to enhance productivity and reduce costs.

What to ExpectHeron Power is an innovative startup dedicated to developing advanced power electronics tailored for the modern energy landscape. Our mission is to eliminate barriers to the expansion of electricity generation and usage through scalable, innovative, and cost-effective hardware solutions, thereby accelerating the electrification of various sectors.Our primary objective is to create superior converters (inverters & rectifiers) that effectively link large-scale renewable energy sources, storage systems, and loads to the grid. Our leadership team consists of experienced professionals who have successfully designed and launched gigawatts of power conversion products over the last decade.We acknowledge that knowledge is collective. Our team will learn extensively together, fostering a collaborative and enriching atmosphere that promotes personal, technical, and career development. You can anticipate working in a fast-paced and collaborative environment, driven by first-principles engineering to tackle complex challenges.Job OverviewAs the Manufacturing Infrastructure Program Manager (Capital Projects Lead) at Heron Power, you will spearhead the execution of essential cross-functional projects that bridge manufacturing, operations, and infrastructure. You will be responsible for the successful delivery of factory readiness initiatives—from inception and construction to production ramp-up—as well as high-impact special projects at our headquarters and factory, including infrastructure enhancements and process optimizations. In this capacity, you will act as both a hands-on engineer and a program leader, defining technical requirements, coordinating with contractors and vendors, aligning internal teams, and ensuring that projects are completed safely, on schedule, and to specifications. You will play a pivotal role in connecting design engineering, manufacturing, and operations, ensuring our facilities and processes are primed to support rapid growth. This is a high-visibility position for an engineer who excels in dynamic settings, relishes building from the ground up, and aspires to influence the foundation of a next-generation hardware manufacturing program—where you will be integral in shaping groundbreaking technology and cultivating a culture of transparency and reliability.How You Will ContributeDesign & Engineering OversightLead the engineering design scope for all facilities and utilities systems (e.g., HVAC, electrical, plumbing, architectural, IT, etc.) for a new manufacturing facility.Define, review, and approve design specifications, engineering drawings, and scope documents provided by an external design-build firm.

What to ExpectAt Heron Power, we are pioneering innovative power electronics solutions designed for the modern grid. Our mission is to eliminate barriers in electricity generation and consumption by developing scalable, cost-effective hardware that propels the electrification of all sectors.Our primary objective is to enhance power converters (inverters & rectifiers) that seamlessly integrate large renewable energy sources, storage systems, and loads into the grid. Our leadership team boasts extensive experience, having successfully designed and delivered gigawatts of power conversion products over the last decade.We believe in collective knowledge and continuous learning. Join us in a collaborative, enriching workplace where personal, technical, and career growth is prioritized. You will thrive in a dynamic environment focused on first principles engineering and tackling complex challenges.Job OverviewWe are seeking a proficient Manufacturing Technician to spearhead engineering builds and assist in the early-stage scaling of complex power electronics assemblies. You will closely collaborate with engineering, manufacturing, operations, and equipment teams to create repeatable processes, execute and monitor unit builds, and support product launch development throughout all engineering lifecycle phases. Your timely and technical feedback will be crucial to enhancing product safety, quality, and reliability. This multifaceted role encourages innovative thinking to achieve excellence in our offerings.How You Will ContributeExecute and facilitate the assembly of complex power electronics through prototype, pilot, and production phases.Lead hands-on troubleshooting, identify issues, and document findings during builds, bring-up, and early manufacturing runs to provide valuable feedback to engineering and project management.Work with cross-functional teams (including manufacturing, hardware engineering, reliability, testing, and operations) to create processes for prototype builds, testing, and troubleshooting protocols across various experimental setups and systems.Document insights and failure modes, analyze data, and communicate with cross-functional teams to implement product enhancements and track incremental improvements.Support the bring-up, validation, and troubleshooting of equipment and testing systems.

Join Heron Power as a Supplier Industrialization Engineer, where you will play a pivotal role in enhancing our supply chain processes and collaborating with suppliers to optimize manufacturing capabilities. You will be responsible for ensuring that supplier operations align with our quality standards and production timelines, contributing to our commitment to innovation and excellence.In this dynamic position, you will utilize your engineering expertise to drive improvements in supplier processes, conduct assessments, and implement best practices that enhance efficiency and reduce costs. Your analytical skills will be key in evaluating supplier performance and providing actionable insights to the team.

Job OverviewAt Heron Power, we are at the forefront of revolutionizing scalable power electronics. Our mission is to facilitate high-volume, cost-effective manufacturing of advanced energy systems. As we rapidly expand our production capabilities, we are looking for a pivotal role to design and implement cutting-edge manufacturing processes that will drive our growth and deliver innovative products to the market.In the role of Factory Automation Engineering Manager, you will spearhead the factory automation strategy at Heron Power. You will assemble and lead a team responsible for the operational backbone of our manufacturing lines, overseeing everything from on-site logic to cloud data integration.This high-impact position requires you to define our automation strategy and establish control standards, selecting the platforms, protocols, and architectures that will seamlessly transition us from pilot lines to large-scale production. You will mentor and manage a team of automation and controls engineers, ensuring collaboration with the broader manufacturing organization to enhance the functionality, efficiency, intelligence, and safety of our equipment.Your ContributionsTeam Leadership: Recruit, mentor, and guide a high-performing team of controls and automation engineers. Cultivate a culture of technical innovation, safety excellence, and continuous improvement.Strategic Vision: Shape the company’s roadmap for controls and automation. Choose standard hardware platforms, software environments, communication protocols, and data systems to guarantee scalability for future factories.Design Standardization: Create and uphold a code library and design standards to accelerate deployment time and enhance control systems reliability.Project Execution: Supervise controls engineering deliverables for capital equipment deployment, managing project timelines, internal resources, and external vendors from conceptual design through Factory Acceptance Testing (FAT) to factory ramp-up.Vendor Management: Act as the primary controls liaison for external machine builders and system integrators. Assess and approve their electrical schematics and software architectures prior to fabrication and programming, and lead debugging and commissioning activities through to final production ramp.

Job OverviewAt Heron Power, we are pioneering the next generation of scalable power electronics. Our goal is to facilitate high-volume, capital-efficient manufacturing of advanced energy systems. As we expand our production capabilities, this role plays a critical part in designing and optimizing cutting-edge manufacturing processes that will support our ongoing growth and bring innovative products to market.In the position of Automation & Controls Engineering Manager, you will be the architect behind Heron Power's factory automation strategy. You will assemble and lead the team that creates the essential framework for our manufacturing lines, managing everything from the operational logic on the factory floor to the data integration in the cloud.This influential role involves establishing our automation strategy and defining control standards, while selecting the platforms, protocols, and architectures that will enable our transition from pilot lines to mass production. You will oversee a team of automation and controls engineers, providing mentorship in best practices and collaborating closely with the larger manufacturing organization to ensure our equipment is not only functional but also efficient, intelligent, and safe.

Zero Motorcycles builds electric motorcycles designed for an instinctive, engaging ride. The company’s Product Experience team shapes every touchpoint between bike and rider, from onboard firmware and dash displays to mobile apps, diagnostic tools, and the cloud platform connecting them all. The Senior Software Engineer - Cloud Platform will help design and develop the systems that move data between motorcycles, mobile applications, and field tools. This cloud platform underpins telemetry, supports technician tools, and ensures seamless connectivity for riders. Engineering choices in this role will directly influence future features, business agility, and the speed of delivering new capabilities. What You’ll Do System Ownership Oversee cloud systems that handle data transfer among motorcycles, mobile apps, and field tools, from infrastructure through deployment pipelines. Guide troubleshooting and problem-solving, working closely with architects to address technical challenges. Mentor junior and mid-level engineers in Python, AWS, and system design, helping to build a self-sufficient team. System Architecture Work with architects to design a platform that lets teams build independently, minimizing cross-team friction. Maintain clear separation and scalability between FastAPI backend, Next.js frontend, and AWS infrastructure. Infrastructure Management Define compute strategies within AWS, weighing cost, reliability, and complexity to select the right services. Monitor and optimize system resources to support a growing fleet and expanding programs. Use AWS CDK to keep infrastructure reproducible and deployable, ensuring production systems are managed as code. Continuous Delivery Own the CI/CD pipeline, making it a core part of the engineering workflow. Keep the pipeline efficient and secure to enable rapid, reliable deployments and quick recovery from issues in the field. Location Scotts Valley, California, United States

Join Heron Power as a Compliance Engineering Technician, where you will play a crucial role in ensuring that our products meet regulatory standards and compliance requirements. This position is ideal for individuals who are detail-oriented and passionate about quality assurance in engineering practices.

What You Can ExpectAt Heron Power, we are a pioneering startup dedicated to developing advanced power electronics tailored for the modern grid. Our mission is to alleviate the constraints on electricity generation and consumption through scalable, innovative, and cost-effective hardware solutions, thereby accelerating the electrification of all sectors.Our primary objective is to engineer superior converters (inverters & rectifiers) that seamlessly integrate large-scale renewable energy sources, energy storage, and loads into the grid. Our leadership team comprises industry veterans who have successfully designed and delivered gigawatts of power conversion products over the last decade.We recognize that collaboration is key to success. We are committed to fostering a learning environment where everyone can grow personally, technically, and in their careers. You will thrive in a dynamic and collaborative setting that emphasizes first-principles engineering and innovative problem-solving.Job OverviewAs our Lead Compliance Engineer, you will be at the forefront of managing the complete safety and compliance lifecycle for our product range. You will spearhead the compliance strategy, engaging early in the development of codes and standards, through to certification, market launch, and ongoing enhancements. Your role is crucial in identifying the regulatory and technical challenges that Heron’s products must navigate to successfully enter global markets. Collaborating closely with the design engineering team, you will ensure that our products not only meet but exceed all regulatory requirements and certifications.Your ContributionsConduct thorough research and interpretation of compliance standards from UL, IEC, IEEE, NEC, ISO, and other regulatory bodies to guide Heron’s successful product listings and market entry strategies.Collaborate with engineering, product, and manufacturing leads throughout the product lifecycle to embed compliance into product design, leveraging creative and analytical problem-solving skills.Develop and implement comprehensive compliance test plans, including the identification and creation of necessary testing infrastructure and resources.Analyze failures and collaborate with engineering teams to develop effective design solutions.Establish and maintain high-performance partnerships with NRTLs to ensure timely certification processes.Define and uphold client test data acceptance programs with NRTLs to streamline our compliance initiatives.

Join Our Innovative TeamAt Heron Power, we are at the forefront of revolutionizing power electronics for the modern grid. As a pioneering startup, we are dedicated to alleviating constraints in electricity generation and consumption through scalable, innovative, and cost-effective hardware solutions, propelling the electrification of various sectors.Our initial focus is to develop advanced converters (inverters & rectifiers) that seamlessly connect large-scale renewable energy sources, energy storage systems, and loads to the power grid. Our leadership team comprises industry veterans who have successfully designed and launched gigawatts of power conversion products over the last decade.We believe in the power of collective learning and collaboration. Our environment fosters personal, technical, and career growth, promoting hands-on execution and problem-solving based on fundamental engineering principles.Role OverviewIn the role of Lead Dielectric Materials Engineer, you will be pivotal in developing and qualifying insulation systems that ensure the reliability of our medium-voltage power conversion products. Your expertise will be crucial in defining the material and process foundations that underpin our products, guaranteeing they perform under rigorous electrical and thermal conditions for decades.You will oversee the complete lifecycle of insulation systems, focusing on materials, interfaces, geometry, and processes to meet stringent electrical, thermal, mechanical, and production specifications. This includes work on dielectric materials, bonding systems, encapsulation, coatings, molding, potting, and composite insulation assemblies. You will establish evaluation criteria for materials, qualification processes, and failure analysis, translating fundamental principles into robust, manufacturable designs.This position is ideal for an engineer who can integrate electric field stress, thermal cycling, material behavior, manufacturing processes, and long-term reliability into cohesive engineering solutions.

Be Part of the Future at Zero Motorcycles!Step away from the ordinary and into the exhilarating world of innovation. At Zero Motorcycles, we lead the charge in electric mobility.Since launching our inaugural Zero S in 2010, we’ve been at the cutting edge of the electric vehicle revolution, crafting award-winning motorcycles and electrifying sport and utility vehicles for top OEMs. Our commitment to pioneering technology and exceptional craftsmanship enables us to redefine performance and sustainability, making every ride an adventure while contributing to a greener planet.Join us and help shape the future of electric transportation.Electrical Engineer III – Powertrain SystemsPosition Overview:We are on the lookout for a proficient Staff Electrical Engineer to enhance our powertrain electrical hardware and systems. This is a unique opportunity to join a highly skilled electric powertrain design team where your contributions will significantly impact design success, team objectives, and overall company goals. Your responsibilities will encompass embedded electronics design, Electrical Wiring Interconnection System (EWIS) development, power electronics design, and integration of powertrain systems. Additionally, you will be pivotal in root cause and corrective action (RCCA) initiatives addressing development, field, and manufacturing challenges. This hands-on role is situated at our R&D facility in Scotts Valley, CA, reporting directly to the Powertrain Systems Engineering Manager.Your Responsibilities:Technical DutiesYou will play a key role in advancing our powertrains through:Defining requirements, CAD design, simulation and analysis, component selection, system bring-up, testing, and supplier support for:Embedded hardware design (ECUs, battery management systems);Electrical Wiring Interconnect Systems (EWIS) development;Power electronics (DC-DC converters, chargers, motor controllers).Designing, testing, and documenting system-level architecture.Engaging in design reviews, RCCA activities, and reviewing test reports.Creating and maintaining design documentation following internal best practices.

Join Heron Power as a Regulatory Compliance Engineer and play a pivotal role in ensuring our products meet industry standards and regulations. In this dynamic position, you will collaborate with cross-functional teams to develop compliance strategies, conduct risk assessments, and prepare necessary documentation. Your expertise will help navigate complex regulations, ensuring the safety and effectiveness of our innovative energy solutions.

About Zero Motorcycles Zero Motorcycles builds electric motorcycles focused on delivering a seamless and engaging riding experience. The company is committed to innovation that makes every ride intuitive and memorable. Role Overview: Software Engineering Manager, Firmware Products This position leads the Firmware Products team in Scotts Valley, California. The group develops and maintains the software that powers Zero’s motorcycles, including the bike’s core firmware, rider dashboard, mobile apps, diagnostic tools, and cloud connectivity. What You Will Do Guide the Firmware Products team responsible for the core functionality of Zero motorcycles. Oversee firmware development for the bike, dashboard, mobile applications, and connectivity tools. Ensure battery performance engineering and test engineering meet high standards for safety and rider satisfaction. Mentor engineers and foster a culture of continuous learning and collaboration. Encourage iterative development and establish feedback loops to keep rider needs at the forefront. What We Value Leadership that empowers and supports engineers. A focus on safety, performance, and reliability in every product feature. Commitment to iterative improvement and open feedback. Dedication to delivering a trusted and satisfying experience for riders. Location This role is based in Scotts Valley, California, United States.

What You Can ExpectAt Heron Power, a pioneering startup focused on revolutionizing power electronics for the modern grid, we are committed to facilitating the growth of electricity generation and consumption through innovative, scalable, and cost-effective hardware solutions. Our mission is to accelerate the electrification of everything.Our primary objective is to develop superior converters (inverters and rectifiers) that integrate large-scale renewable energy sources, storage systems, and critical loads such as data centers into the grid. With a leadership team comprised of industry veterans who have successfully designed and delivered gigawatts of power conversion products, we are well-equipped for this challenge.We recognize that collaboration is key to learning and growth. Our team-oriented environment fosters personal, technical, and career development, ensuring that you will gain valuable insights as you tackle complex engineering problems alongside experienced professionals.

What You Can ExpectAt Heron Power, we are pioneering innovative power electronics designed for the modern grid. Our mission is to alleviate the challenges associated with electricity generation and consumption through scalable and cost-effective hardware solutions that foster the electrification of various sectors.Our primary focus is on developing advanced converters (including inverters and rectifiers) that efficiently integrate large-scale renewable energy sources, storage systems, and electrical loads into the grid. The leadership team at Heron Power comprises industry veterans with extensive experience in designing and deploying gigawatts of power conversion technologies over the past decade.We believe in the power of collaborative learning, where every team member contributes to and learns from one another. Our dynamic environment encourages personal, technical, and professional growth, driven by foundational engineering principles and a commitment to tackling complex challenges.Internship OverviewAs a Power Electronics Intern, you will collaborate with a team of seasoned engineers to design, develop, and validate state-of-the-art medium-voltage power electronics systems. This internship offers a unique opportunity to engage with hands-on projects, contribute to essential product development efforts, and enhance your knowledge of high-voltage systems, power converter designs, and control mechanisms. You will participate in all phases of the hardware development lifecycle—from conceptualization and modeling to prototyping and testing—while working cross-functionally with firmware, mechanical design, validation, and manufacturing teams.This internship is perfect for students who are passionate about power electronics and eager to create scalable, efficient, and reliable energy systems that will influence the future of the grid.

What to ExpectHeron Power is a pioneering startup dedicated to developing state-of-the-art power electronics for the modern grid. Our mission is to alleviate barriers in electricity generation and consumption through scalable, innovative, and cost-effective hardware solutions, thereby propelling the electrification of everything.Our primary objective is to create superior converters (inverters & rectifiers) that facilitate the connection of large-scale renewable energy sources, storage systems, and loads to the grid. Our leadership comprises industry veterans with extensive experience in designing and deploying gigawatts of power conversion products over the last decade.At Heron Power, we recognize that knowledge is collective. We are committed to mutual learning and fostering a collaborative and stimulating environment that promotes personal, technical, and career development. Expect to engage in a dynamic setting driven by first principles engineering, tackling complex challenges together.

Heron Power designs hardware for the evolving electric grid, with a focus on scalable, cost-effective power electronics. The team develops advanced converters such as inverters and rectifiers, connecting renewable energy, storage, and large-scale loads to the grid. Leadership at Heron Power brings significant experience, having delivered gigawatts of power conversion products. Collaboration is central to Heron Power’s culture. Every team member’s perspective is valued, and engineers work together to solve complex challenges. The environment supports both personal and technical growth. Role overview The Platform Engineering Intern will join the Software team for a hands-on introduction to platform software infrastructure. This internship centers on learning and supporting tools that help engineers build and deploy software, from cloud environments to deployment pipelines. Curiosity, willingness to learn, and follow-through are more important than prior professional experience. What you will do Cloud and infrastructure setup: Assist with provisioning and organizing AWS resources. Learn to use infrastructure-as-code tools like Terraform or Pulumi, with training provided. CI/CD pipelines: Support the creation of pipelines that move code from development to production. Become familiar with GitHub Actions and deployment workflows. Kubernetes basics: Help set up a Kubernetes cluster and explore how applications run in containers in production environments. Developer tooling: Contribute to internal scripts and tools that automate tasks and improve engineering efficiency. Observability and monitoring: Assist with setting up dashboards and alerts using Grafana or Prometheus to help the team monitor systems. Security basics: Gain exposure to access control setup and support ongoing security efforts. Location This internship is based in Scotts Valley.

What to ExpectJoin Heron Power, an innovative startup revolutionizing power electronics for the modern electrical grid. Our mission is to enhance the efficiency of electricity generation and consumption through scalable and cost-effective hardware solutions, thereby accelerating the electrification of various sectors.Our initial focus is on developing advanced converters (inverters and rectifiers) that seamlessly integrate large-scale renewable energy sources, storage systems, and load management into the electrical grid. Our leadership team boasts extensive experience, having designed and delivered gigawatts of power conversion products over the last decade.At Heron Power, we believe in collective learning and personal growth within a supportive and collaborative environment. You will thrive in a dynamic workspace where first principles engineering is applied to tackle challenging problems.Job OverviewAs a Power Magnetics Engineer Intern, you will play a key role in the design, validation, and characterization of magnetic components that are essential for high-efficiency, high-power, medium-voltage converter systems.Magnetic components are vital for optimizing converter performance, efficiency, thermal dynamics, and electromagnetic compatibility. In this internship, you will collaborate closely with power electronics engineers to validate inductors, transformers, planar magnetics, magnetic current sensors, and EMI filtering components utilized in high-frequency, resonant, and multi-level converters. You will assist in characterizing magnetic performance, analyzing electromagnetic behavior, and connecting experimental results with analytical and simulation models.This internship offers hands-on experience with real power converter hardware and magnetics, supporting engineering efforts from initial prototype assessment to comprehensive system validation.

Join Us at Heron PowerHeron Power is an innovative startup dedicated to revolutionizing power electronics for the modern grid. Our mission is to facilitate the growth of electricity generation and consumption through scalable, cost-effective hardware solutions, thus speeding up the electrification of diverse sectors.Our primary objective is to enhance power converters (inverters and rectifiers) that connect large-scale renewable energy sources, storage solutions, and loads to the grid. Our leadership team consists of industry veterans who have extensive experience in designing and deploying gigawatts of power conversion technology over the last decade.At Heron Power, we believe in collective learning and fostering a collaborative and enriching atmosphere that encourages personal, technical, and career growth. Expect to engage in a dynamic environment driven by first-principles engineering as we tackle complex challenges together.Role OverviewAs the Capital Projects Lead, you will be instrumental in driving the execution of cross-functional projects that merge manufacturing, operations, and infrastructure. You will oversee factory readiness initiatives from conception and construction through to production ramp-up, as well as high-impact projects at both headquarters and the factory, including infrastructure enhancements and process refinements. This role will require you to act as both a hands-on engineer and a program leader, defining technical requirements, coordinating with contractors and vendors, aligning internal teams, and ensuring that all projects are executed safely, on time, and according to specifications. You will serve as the crucial link between design engineering, manufacturing, and operations, ensuring that our facilities and processes can support our rapid growth. This position is ideal for an engineer who thrives in dynamic settings, enjoys building from the ground up, and is eager to lay the groundwork for a next-generation hardware manufacturing program.Your ContributionsDesign & Engineering LeadershipLead the engineering design aspects for all facility and utility systems (including HVAC, electrical, plumbing, architectural, IT, etc.) for a new manufacturing facility.Define, review, and approve design specifications, engineering drawings, and scope documents from an external design-build firm.