Senior Manager, Linear Electric Machines Principal

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 Senior Manager, Linear Electric Machines Principal is responsible for the Linear Electric Machine (LEM), the permanent-magnet linear motor/generator at the heart of every KARNO™ generator. Each 200 kW KARNO Core uses four LEMs to convert free-piston motion into power on a native 800 VDC bus, and the same machine is the building block for Hyliion’s multi-megawatt U.S. Navy and data center systems. This position is the single technical authority and people leader for the LEM, accountable for electromagnetic and mechanical design, insulation and materials, test and qualification, certification, and supplier and manufacturing readiness across the current production machine and future generations. The role leads the LEM engineering team in the Cedar Park, TX to scale in-house LEM production to volume at target cost, yield, and reliability and partner with the Hyliion R&D team in Cincinnati, OH. 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 • Design authority: Serve as the single accountable technical owner for the KARNO LEM across its lifecycle (requirements, architecture, design, verification, release, production, and field performance) for both the current production design and future generations. • Team leadership: Lead, hire, and develop a team of electromagnetic, mechanical, and design engineers; set priorities, run technical reviews, and build the standards, design tools, and processes the team needs to scale with the business. • Electromagnetic design: Own electromagnetic design and optimization of tubular permanent-magnet linear machines, including topology, magnet and winding design, magnetic circuit, force constant, cogging/detent force, losses, efficiency, and demagnetization margin, using 2D/3D FEA and analytical models correlated to test data. • Mechanical design: Own translator, stator, and housing mechanical design, including translator structural integrity and fatigue of high-cycle reciprocating components, air-gap eccentricity and radial side load, tolerance stack-ups and GD&T, thermal management, and mechanical interfaces to the KARNO Core and position sensing. • Insulation and thermal: Own the stator insulation system and thermal design, including insulation materials and processes, temperature sensing, partial discharge and E-field stress under inverter-fed operation, thermal modeling, and thermal aging for long-life continuous duty. • Machine–drive integration: Partner with power electronics, controls, and systems teams on machine–drive co-design: 800 VDC architecture, inverter interface, position feedback, and transient load-step performance. • Next-generation roadmap: Define and execute the LEM technology roadmap for higher power density, higher efficiency, and lower cost, including topology and magnet-array studies, coil and core concepts, and scaling for multi-megawatt KARNO systems. • Manufacturing scale-up: Lead DFM/DFA for the in-house LEM line: define critical-to-quality characteristics and process windows for stator and translator manufacturing and assembly; drive fixtures, tooling, work instructions, travelers, and repair procedures; and improve yield, cycle time, and cost from prototype rates to volume production. • Test and validation: Define the LEM verification an