Note: The job is a remote job and is open to candidates in USA. Amphenol TCS 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.
Responsibilities
- 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
- 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
- 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
Skills
- 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: Contact systems (high current, low resistance, plating, wear), Sealing systems (IP-rated connectors, gaskets, environmental protection), Strain 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
- Proven leadership experience with ability to influence across engineering, manufacturing, and customer functions
- Excellent written and verbal communication skills in English, with ability to operate in a global, cross-functional environment
- Advanced problem-solving abilities and data-driven decision making under limited direction
- Proficiency in Microsoft Office and collaboration platforms (Teams, Outlook, Excel, PowerPoint, etc.)
- 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
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