Firmware Hardware Design Engineer Jobs in Appleton, WI

If you think in transfer functions and Bode plots but still love the smell of a freshly stuffed prototype board, keep reading. Miller Electric Mfg. LLC, a leading U.S. designer and manufacturer of welding equipment, is growing its Central Engineering team.  We are looking for a Senior Power Electronics & Controls Engineer whose deep power electronics instinct is backed by solid control theory; someone who can model a plant, close a loop, and then prove it on the bench.  This is advanced development: you will evaluate technologies, deliver proof-of-concept prototypes, and build the design libraries and reference architectures that our divisions turn into the products that welders depend on.  The technologies and architectures you develop will become the foundation for future Miller welding platforms used by customers around the world.   

You will work elbow-to-elbow with electrical, software, mechanical, and weld engineers, and partner with division representatives to deliver what they need to delight our customers.  Whether you prefer Milwaukee's urban energy or the exceptional quality of life, affordability, and outdoor access of Wisconsin's Fox Valley, you'll find a strong engineering community, room to make an outsized impact, and the freedom to spend less time commuting and more time building great technology.  If building the platform behind the product is the kind of challenge that excites you, let's talk. If you're the sort of engineer who can turn theory into hardware and hardware into results, you'll fit right in.  You don't need to check every box; if your strengths are rooted in controls, power conversion, and bringing ideas to life, we'd love to hear from you!

How you will make an impact: 

• Architect and model the control systems that define how the next generation of welding engines behave. 

• Take new power conversion concepts from control simulation to working proof-of-concept prototypes that show what is possible. 

• Create the reference designs that help our divisions reach the market faster and with less risk. 

• Prove out emerging power conversion technology and define what it takes to make it robust, manufacturable, and repeatable. 

• Partner with division representatives to turn their customer needs into the right technology bets. 

• Mentor across the engineering community and raise the bar for control and power electronics design throughout Miller. 

What you need to be successful in this role: 

• Power electronics command – You bring hands-on mastery of multi-kW switch-mode conversion, including hard-switched full-bridge topologies, SiC and other wide-bandgap devices, gate drive, and magnetics. 

• Control theory depth – You are fluent in feedback control, plant modeling, loop compensation, and analog and digital control.  Whether you came up through controls, power electronics, or both, you understand how to design, analyze, and validate stable high-performance systems. 

• Real-world implementation – You put that theory to work, implementing control laws on microcontrollers or DSPs with hands-on experience in hardware bring-up, ADC and PWM peripherals, and timing-critical firmware. 

• A systems lens – You connect control, power stage, thermal, EMC, and manufacturability so the whole technology wins, not just the loop. 

• Bench instinct – You trust hard measurements over assumptions and love proving a design in copper and silicon, not just in simulation. 

• Curiosity and ownership – You are self-directed, customer-focused, eager to learn, and ready to roll up your sleeves when the project calls for it. 

Minimum education and experience: 

• Bachelor's Degree in Electrical Engineering required; an advanced degree with a controls or power electronics focus is a plus. 

• 5-10+ years of relevant control systems and power electronics experience, or 5+ years for an exceptional engineer who has been a key contributor across many successful designs. 

• Demonstrated experience designing and stabilizing digital control loops for switch-mode power conversion. 

• Proven multi-kW switch-mode design experience, including SiC or other wide-bandgap devices, full-bridge topologies, gate drive, and magnetics. 

• A track record of taking concepts from modeling and simulation through working hardware and measured results. 

• Working knowledge of PCB layout for power and mixed-signal designs, with familiarity with design-for-manufacturing and third-party standards such as UL, CSA, and CE. 

• A self-starter with strong analytical instincts who thrives in a hands-on R&D environment. 

Why ITW Welding? 

At ITW Welding, we’re not just a place to work – we’re a community that empowers you to grow and make a real impact. Join us and build a career that makes a difference! 

Here are some benefits we offer to help you build the future you want: 

• Generous Retirement Benefits – 401(k) match PLUS an additional retirement contribution to help you plan for the future. 

• Paid Time Off – 11 paid holidays, 5 sick days, and vacation time to take time for what matters. 

• Company-Paid Insurance – Life, AD&D, Short-Term &Long-Term Disability insurance to give you peace of mind. 

• Family-Friendly Benefits – 4 weeks of paid parental leave and adoption reimbursement to support your family journey. 

• Education Assistance – tuition reimbursement; because we believe in investing in your personal and professional development. 

• Relocation Assistance – Relocation support is available for qualified candidates joining our team in Milwaukee or Appleton, WI. 

Company Description: 

Comprised of a market-leading portfolio of best-in-class brands, the businesses of ITW Welding work together to provide premium performance delivered through a breadth of solutions encompassing welding, cutting, consumables, and accessories. ITW Welding North America represents Miller Electric Welding Equipment, Safety & Accessories, Hobart Filler Metals, and Bernard / Tregaskiss MIG Guns. 

Miller Electric Mfg. LLC, is headquartered in Appleton, Wisconsin, and wholly owned by Illinois Tool Works (NYSE: ITW).  The company maintains its industry leadership by setting the standard for reliability, quality and responsiveness. Our tagline, “The Power of Blue®,” is inspired by the blue color of Miller equipment. 

The company began with an innovation that responded to customer needs, growing from a one-man operation in 1929, to the world’s largest manufacturer of arc welding products.  Miller keeps the tradition alive by focusing on its top priority: people.