Automotive Aluminum PCB Layout Designer (MCPCB) – LED Taillight Conversion Kits

Project Overview: I run a custom automotive electronics company specializing in premium LED taillight conversion kits for vintage luxury vehicles. Currently, our kits are built completely by hand using aluminum plates, chassis-mount gold resistors, and integrated cooling fans to handle heat and satisfy the factory bulb failure detection system. We are looking for an experienced electronics engineer to help us move away from hand-assembly by designing a compact, rugged, and highly reliable Aluminum Core PCB (MCPCB) to handle all circuit routing and passive thermal management. The Current Circuit & Goals: Input: Factory 12V–14.4V automotive power inputs (Running lights, Brake, Turn signals, Reverse). Bulb Simulation: We use power resistors to load the turn signal and brake circuits to prevent dash warning lights/hyper-flashing. LED Dimming Logic: We currently use power resistors and steering diodes to handle dual-intensity functions (Running vs. Brake). We want to replace the running light resistor with a dedicated automotive linear LED driver IC (e.g., TI TPS92611 or similar) to handle the dimming logic efficiently and minimize continuous heat generation. Thermal Management: The board must rely entirely on passive cooling via the aluminum substrate. No active fans. High-wattage components must use appropriate surface-mount packages (e.g., DPAK / D2PAK / TO-263) with maximized copper ground planes. Connections: No loose wires. The board should feature edge-mounted automotive pin headers or terminal blocks to interface with a pre-crimped wire harness. Physical Constraints: The board must be compact and fit within a footprint of roughly 4” x 4”. Must include ⁠4 mounting holes on the corners for mechanical fastening inside the taillight housing. Required Deliverables: 1. Schematic design and PCB layout files (KiCad or EasyEDA preferred). 2. Manufacturing-ready Gerber files (including drill files, assembly sheets, pick-and-place files). 3. BOM (Bill of Materials) and CPL (Component Placement List) formatted specifically for automated SMT assembly via JLCPCB or PCBWay. Required Skills: Proven experience with Automotive Electronics (handling 12V systems, reverse polarity, and alternator voltage spikes). Experience designing with Metal Core PCBs (MCPCB / Aluminum substrate) and managing thermal dissipation. Familiarity with DFM (Design for Manufacturing) guidelines for quick-turn prototype houses.