Staff Engineer – Product Development (Contact Systems)

Amphenol Communications Solutions (ACS) is a leader in interconnect solutions for various electronics markets. They are seeking a Staff Engineer to lead product development initiatives, focusing on power connectors and cable assembly solutions, while driving technical direction and delivering innovative solutions.

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

Requirements:

• 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