Direct Connection is expanding its portfolio of aftermarket performance parts and looking for a hands-on Electrical Engineer to own the design, validation, and release of wiring harnesses, electronic control modules, and performance electronics. You'll work across concepts, prototyping, lab and vehicle validation, and production launch-partnering with mechanical, calibration, and motorsports teams to deliver reliable, track-proven performance.
What You'll Do (Key Responsibilities)
Harness Engineering
Design low- and high-current 12V/48V wiring harnesses and power distribution for performance applications (engine swaps, crate engines, upgraded fuel/ignition systems, add-on modules).
Create schematics, pinouts, and drawings; select connectors/terminals (e.g., Deutsch, TE/Delphi, Molex), wire spec, shielding, protection, and grommets.
Define harness routing, bundling, sleeving, labels, and heat/abrasion protection suitable for under-hood and motorsport environments.
Author and build documentation, BOMs, and support work instructions and QC criteria for internal or contract manufacturing.
Modules & Electronics
Architect and develop aftermarket control modules (e.g., add-on ECUs, I/O expanders, signal conditioners, power control, sensor interfaces).
Perform PCB bring-up, bench testing, and basic firmware integration (C/C++ preferred) for diagnostics and I/O control.
Implement vehicle network communications.
Support ECU calibration workflows (signals/IO, logging, flashing) in partnership with powertrain calibration.
Validation & Compliance
Build and execute DVP&R plans (bench, HIL/sim, vehicle, dyno/track); capture test data and publish reports.
Conduct EMI/EMC pre-compliance checks and collaborate with labs for formal testing; drive design-for-EMC improvements.
Perform environmental & durability validation (thermal, vibration, ingress, load-dump/transients).
Complete DFMEA for harnesses/modules and implement design controls for reliability and safety.
Ensure compatibility with OEM systems (body, powertrain, and safety where applicable) without adverse interactions.
Diagnostics & Tools
Develop and maintain diagnostic strategies, pinout guides, and service procedures for installers and customers.
Build test fixtures, breakout boxes, and automated test scripts for verification and end-of-line testing.
Provide technical support to tech line, field engineers, and key customers; assist with installation guides and training materials.
Cross-Functional & Supplier Engagement
Collaborate with purchasing, suppliers, and CM partners on DFM/DFx, PPAP/FAI (as applicable), and cost/quality tradeoffs.
Manage change control (CNs), maintain revision control, and support production issue resolution.
Basic Qualifications:
Bachelors Degree in Electrical Engineering or related degree field
8 or more years of hands-on automotive electronics experience (aftermarket or OEM/tier-1)
Proficiency in:
Vehicle networking: CAN/CAN FD, LIN; Vector CANalyzer/CANoe (or equivalent).
Harness design: schematic capture, connector/terminal selection, crimp validation, wire derating, grounding/shielding best practices
Lab instrumentation: oscilloscopes, DMMs, power supplies, electronic loads, logic analyzers
Diagnostics: OBD-II basics, UDS services, flashing, DTCs, and data logging.
Track record of delivering hardware from prototype to production with clear documentation and test evidence
Strong hands-on skills: soldering, rework, crimping, harness assembly/proofing, and safe vehicle test practices
Preferred Qualifications:
MATLAB/Simulink for controls/prototyping; Altium or similar for PCB design; LTspice for circuit analysis
Exposure to high-current systems (fuel pumps, fans, ignition coils), load-dump/transient protection, and MOSFET/H-bridge designs
Familiarity with ISO 7637, CISPR 25/UNECE R10 (EMC), and practical aspects of ISO 26262 (awareness level) as applicable to aftermarket
High-voltage (HV) safety awareness for future hybrid/EV performance accessories (interlocks, isolation, creepage/clearance)
Motorsports/track testing experience and safe dyno procedures