Hybrid Senior Principal R&D/Product Development Engineer

at TE Connectivity

• Job title: Senior Principal R&D/Product Development Engineer
• Job type: Full Time
• Experience level: Lead
• Salary: Not specified
• Degree requirement: Bachelor's Degree
• Location requirements: Hybrid, United States

About the role

• Principal Mechanical Engineer leading advanced mechanical designs for cutting-edge electro-mechanical systems in AI data centers. Collaborating with cross-functional teams to enhance product performance and reliability.

Responsibilities

• Lead development of advanced mechanical architectures for complex electro-mechanical systems, including connector enclosures, latch mechanisms, thermal solutions, and structural interfaces.
• Translate complex real-world mechanical challenges into simulation-driven solutions using Finite Element Analysis (FEA), applying both implicit and explicit methods.
• Own execution of multi-physics simulations—linear and non-linear—across structural, thermal, vibrational, and dynamic load cases using advanced simulation tools (e.g., Ansys Workbench, LS-DYNA, HyperMesh, Simufact, Digimat).
• Guide material selection and qualification, focusing on emerging polymers, composites, TIMs, and metal alloys to meet performance, cost, and reliability goals.
• Define and enforce best practices in design-for-manufacturing (DFM), tolerance stack-up analysis, and robust mechanical design for high-volume production.
• Partner with manufacturing, tooling, and supply chain teams to drive scalable solutions from concept to NPI and mass production.
• Lead technical reviews, design audits, and FMEA processes for high-risk mechanical designs.
• Mentor and coach junior engineers, establishing a culture of technical rigor, innovation, and continuous improvement across mechanical teams.
• Develop and validate reliability test strategies for shock, vibration, thermal cycling, and mechanical fatigue aligned with product application requirements.
• Drive standardization of mechanical design platforms and reusable modules across TE product lines.
• Influence internal and external stakeholders through clear technical communication, cross-functional leadership, and participation in industry forums.
• Support long-term technology planning by contributing to mechanical innovation roadmaps in alignment with CTO and BU strategies.

Requirements

• Bachelor’s degree in Mechanical Engineering or Physics with 12+ years of experience, or Master's with 10+ years of experience, or PhD with 6+ years of experience, 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.

Benefits

• Health insurance
• 401(k) matching
• Flexible work hours
• Paid time off
• Remote work options