STAFF- Thermal Analysis| R&D/PRODUCT DVL ENGINEER

At TE, you will unleash your potential working with people from diverse backgrounds and industries to create a safer, sustainable and more connected world. 
Job Overview

As a Staff Mechanical Product Development Engineer in the Mechanical Center of Excellence, you will lead advanced mechanical research, design, and validation efforts for cutting-edge interconnect systems used in AI data centers, high-performance computing, and next-generation communication infrastructure.

Your role involves developing novel mechanical structures, executing thermomechanical simulations, validating materials, and collaborating cross-functionally to enhance product performance, reliability, and manufacturability. You will operate with a high degree of autonomy and technical depth to define and drive innovation across mechanical platforms—from early-stage PoCs through NPI handoff.

This role is highly cross-functional, requiring collaboration with electrical, signal integrity, system architecture, manufacturing, and supplier development teams.

Job Requirements

•    Bachelor's degree in Mechanical Engineering or Physics with 8+ years of experience, or a Masters degree in Mechanical Engineering or Physics, or equivalent amount of experience in mechanical product development in connector, electronics, or high-reliability hardware industries. 

•    Hands-on experience with mechanical design and modeling using tools such as Creo, SolidWorks, or NX.

•    Expertise in simulation tools such as ANSYS, Abaqus, or FloTHERM for thermal/structural analysis.

•    Proven experience in DFM, DFA, and transition of mechanical designs to high-volume manufacturing.

•    Deep understanding of materials science, including polymers, metals, and thermal materials.

•    Experience conducting reliability testing: thermal cycling, vibration, drop/shock, and HALT/HASS.

•    Strong problem-solving and analytical skills with a focus on root cause analysis and continuous improvement.

•    Excellent communication skills to engage with global engineering, operations, and customer teams.

Job Responsibilities

•    Drive development of advanced mechanical platforms for interconnect systems, including housings, latches, thermal solutions, and structural supports.

•    Lead thermomechanical simulation (FEA/CFD) activities to optimize mechanical performance, thermal management, and structural integrity.

•    Translate real-world mechanical challenges into FEA models, using both implicit and explicit analysis methods to evaluate component behavior under different physical conditions (e.g., structural, thermal, vibration, shock).

•    Utilize advanced simulation tools such as Ansys Workbench, LS-DYNA, HyperMesh, Simufact, and Digimat to perform both linear and non-linear analyses and evaluate material and structural responses under diverse loading scenarios.

•    Conduct root cause analysis and develop mitigation plans for mechanical challenges related to warpage, fatigue, insertion force, material failures, etc.

•    Champion material and process innovation by evaluating composites, thermal interface materials (TIMs), and micro-structured mechanical designs.

•    Create standardized mechanical modules for reuse across product families, aligned with design-for-manufacture and platforming strategies.

•    Partner with manufacturing and tooling teams to ensure early DFM/DFA integration and fast prototyping of mechanical solutions.

•    Develop and validate test plans for thermal cycling, vibration, shock, and environmental reliability.

•    Generate and maintain design standards, mechanical guidelines, and mechanical review frameworks across TE D&D.

•    Mentor junior engineers and support global mechanical design communities through technical forums, training, and documentation.

•    Collaborate with CTO, AMP, and BU engineering teams to align on mechanical technology roadmaps and influence long-term innovation direction.

Competencies Values: Integrity, Accountability, Inclusion, Innovation, Teamwork

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