Staff Development Engineer – Power Connectors

Job Overview

Our client a world leader in interconnect solutions for Communications, Mobile, RF, Optics, and Commercial electronics markets. The Power Solutions group is seeking a Staff Engineer to lead product development initiatives across power connectors and cable assembly solutions. This role plays a critical part in shaping technical direction and delivering innovative, high-quality, and cost-effective solutions that meet market and customer demands.

The ideal candidate will be a strategic technical leader with a strong background in mechanical and electro-mechanical design, including power connector architecture, contact system design, sealing, and cable interface solutions, with a proven ability to drive cross-functional collaboration and mentor engineering talent.

Responsibilities:

Technical Leadership

•Lead design reviews, ensuring technical rigor, cross-functional alignment, and alignment to customer expectations.

•Drive cost reduction through innovative design, material optimization, and manufacturing improvements.

•Introduce and champion new technologies, tools, and design techniques to enhance performance and efficiency.

•Provide deep technical guidance and mentorship across the product development lifecycle.

•Lead training programs to elevate engineering capability, especially in power connector design and applications.

•Capture lessons-learned and implement best practices and standardized design approaches.

Product Development & Execution

•Support full-cycle development of power connectors, contact systems, and cable assemblies from concept through production.

•Design and optimize electrical contact systems (current carrying capability, contact resistance, thermal performance, plating, and durability).

•Develop robust strain relief solutions to ensure mechanical integrity and long-term reliability of cable-to-connector interfaces.

•Design sealed connectors and interfaces, including gasket selection, IP rating compliance, and environmental performance (dust, water, temperature).

•Translate Voice of Customer (VOC) into clear engineering specifications through close collaboration with customers and internal teams.

•Perform concept development, feasibility studies, and mechanical/thermal simulations.

•Create 2D/3D CAD designs (Creo preferred), conduct DFMEA, and perform tolerance stack-up analysis.

•Build prototypes, execute validation testing, and lead product qualification to final release.

•Ensure designs meet electrical, mechanical, and environmental requirements across applications.

•Support manufacturing, tooling, and quality teams for successful product launch.

•Manage product issues, ECNs/PCNs, and drive continuous improvement.

Process, Collaboration & Strategy

•Provide technical documentation including design history files, drawings, engineering change notices, and qualification reports.

•Collaborate with global teams, procurement, and suppliers to meet all quality, technical, and cost targets.

•Maintain awareness of competitor technologies and contribute to the strategic IP positioning of new designs. Generate and maintain technical documentation (drawings, specifications, DFMEA, validation reports, DHF).

•Collaborate with global engineering, procurement, and suppliers to meet cost, quality, and delivery targets.

•Drive Design for Manufacturability (DFM) and Design for Assembly (DFA) for connector and cable solutions.

•Maintain awareness of industry trends and contribute to innovation and IP strategy in power connectivity.

Required Qualifications:

•Master’s degree in engineering.

•Minimum 6 years of experience in mechanical design and product development within electrical components, connector systems, or cable assemblies.

•Strong expertise in connector design (preferably power connectors), including:

oContact systems (high current, low resistance, plating, wear)

oSealing systems (IP-rated connectors, gaskets, environmental protection)

oStrain relief and cable interface design

•Strong background in connector, or cable assembly design and related manufacturing processes (stamping, molding, assembly, plating).

•Expertise in 3D CAD design (preferably Creo), PDM tools, GD&T, and limit/tolerance analysis.

•Proficient with FEA software (Ansys/Workbench) for mechanical simulation involving elastic/plastic deformation.

•Skilled in creating product specifications, design documentation, and conducting DFMEA and validation testing.

•Solid understanding of Design for Manufacturing (DFM) and experience launching designs into production.

•Advanced problem-solving abilities and data-driven decision making under limited direction.

•Strong experience in designing latching mechanisms, sealing mechanisms, and plastic injection molded parts.

•Knowledge of product design methodologies: GD&T, DFM, DFMEA, statistical tolerance stack analysis.

•Experience in product testing, validation processes, and qualification protocols.

•Understanding of Six Sigma and statistical process control (DFSS knowledge is a plus).

•Strong communication skills with the ability to effectively present technical information to global customers and internal stakeholders.

•Ability to prioritize and manage multiple projects simultaneously with minimal supervision.

•Knowledge of global industry standards and regulatory certifications (e.g., UL, IEC, EIA).

•High technical aptitude and willingness to continually learn and adapt to new technologies.

•Up to 25% travel domestically and internationally.