The Senior Prototype Technician – Boost Systems is a technical expert responsible for leading the hands-on assembly, testing, and validation of prototype turbocharger boost control hardware and systems across multiple engine platforms. This role involves detailed integration of actuators, sensors, and control components on test engines and vehicles, managing complex test setups, troubleshooting prototype issues, and supporting development goals. The senior technician mentors junior staff, drives process improvements, and collaborates closely with engineering and calibration teams.
Prototype Assembly & Integration
Lead the assembly and installation of advanced boost control components including wastegates, variable geometry turbos (VGT), electronic actuators, and sensors on prototype engines and test vehicles.
Manage complex wiring harness integration, sensor calibration setups, and actuator installations ensuring prototype readiness for testing.
Testing & Validation
Plan, set up, and execute comprehensive test procedures on dynos and vehicle test platforms to validate boost system performance and durability.
Conduct functional and diagnostic testing on prototype components including actuator response, sensor accuracy, and control valve behavior under varied conditions.
Troubleshooting & Problem Resolution
Lead troubleshooting efforts to identify mechanical, electrical, or software issues affecting prototype boost control systems.
Provide root cause analysis and collaborate with engineering teams to develop corrective actions or design refinements.
Process Leadership & Documentation
Develop and maintain detailed test documentation, build records, and change logs to support traceability and project milestones.
Mentor junior prototype technicians on assembly techniques, test procedures, and safety protocols.
Drive continuous improvement initiatives to optimize prototype assembly and test workflows.
Leadership in prototype assembly and integration of boost control hardware
Execution and management of complex dyno and vehicle test protocols
Advanced troubleshooting of mechanical, electrical, and integration issues
Collaboration with engineering and calibration teams on prototype refinement
Mentorship and development of junior technical staff
Ensuring quality, safety, and documentation compliance in prototype environments
Education:
Associate degree or Bachelor’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics, or related technical field required
Experience:
5–8+ years of experience in prototype assembly, automotive test, or powertrain development roles
Proven track record working with turbocharger boost control hardware and test environments
Experience leading prototype assembly and test teams preferred
Technical Skills:
Expertise in mechanical assembly and integration of boost actuators, wastegates, VGTs, and sensors
Proficient in dyno operation, test bench setups, and data acquisition tools
Strong troubleshooting skills for mechanical, electrical, and control system issues
Familiarity with wiring harnesses, sensor calibration, and ECU interfaces
Soft Skills:
Strong leadership and mentorship abilities
Excellent communication and teamwork skills
Ability to manage multiple priorities and lead complex projects
Detail-oriented with strong documentation and quality focus