Engineer, Test & Validation

Hyliion is committed to creating innovative solutions that enable clean, flexible and affordable electricity production. The Company’s primary focus is to develop distributed power generators that can operate on various fuel sources to future-proof against an ever-changing energy economy. Job Purpose The Engineer, Test & Validation is responsible for converting engineering and customer objectives into measured and validated results on the KARNO development team. The role covers the full test cycle: defining the test, assembling and instrumenting the hardware, executing the run, reducing the data, and presenting conclusions in technical review. Work spans KARNO Power Modules and Cores, linear generator and motor dynamometers, and component and subsystem rigs, and the resulting data directly informs program decisions. Because KARNO departs from conventional reciprocating and turbine architectures, using flameless oxidation to drive sealed helium through a thermodynamic cycle with a single magnet-carrying piston per shaft on pressurized helium bearings generating native 800 VDC, no established test methodology exists for a machine of this type. This position therefore carries significant influence over the test methods, rigs, and acceptance criteria against which KARNO is validated. AI at Hyliion At Hyliion, AI is core to how we work. We equip every team member with leading AI tools and count on you to use them — to move faster, solve harder problems, and help us realize the full potential of KARNO technology for the world. Duties and Responsibilities • Operate KARNO Power Modules and Cores through startup, steady-state, step-load, load-acceptance and load-rejection, endurance, thermal cycling, and fuel-switching sequences, evaluated against defined acceptance criteria including ISO 8528 performance classes and program-specific targets. • Operate and maintain linear generator and motor dynamometers, resistive and reactive load banks, and the associated power measurement chain, characterizing efficiency, force, thermal limits, and controls behavior across the operating envelope. • Commission and operate regenerator, heat exchanger, burner, seal, bearing, and pressure vessel rigs, covering flow, pressure drop, effectiveness, leak rate, durability, and life testing on the components that set KARNO's performance. • Perform mechanical assembly of test articles and rigs, including instrumentation installation and routing, harness build, gas and coolant plumbing, sensor calibration, channel checkout, and rig commissioning. • Design, procure, and fabricate fixtures, adapters, brackets, ducting, and tooling where no suitable off-the-shelf solution exists, including CAD models, drawings, and as-built documentation. • Translate engineering objectives into test plans, DVP&R entries, test matrices, instrumentation lists, run sheets, and acceptance criteria, including the hazard analysis required to release a test for execution. • Configure data acquisition and cell automation systems, select sampling rates and filtering, manage calibration and measurement uncertainty, and maintain data integrity across the full acquisition chain. • Lead teardown and root cause investigation of hardware failures and test escapes, drive corrective actions to closure with the responsible design owners, and incorporate findings into subsequent builds. • Manage cell scheduling and utilization, preventive maintenance, calibration intervals, spares and consumables, and test asset readiness. • Enforce the safety practices governing high-pressure helium, combustible fuels, elevated temperatures, and 800 VDC systems. • Publish test reports promptly following test completion, documenting calibrated channels, quantified measurement uncertainty, and results th