Staff R&D/Product DVL Engineer

Job Overview

The Staff Manufacturing & Process Development Engineer will serve as the technical lead for inventing novel manufacturing approaches and reimagining established processes to enable the next generation of connectors and connector components within TE's Advanced Development (AD) organization. This role drives creative process innovation — applying, adapting, and combining known techniques such as laser machining, stamping, molding, and micro-fabrication in new configurations to solve complex connector design challenges. The engineer will be central to translating bold connector concepts into manufacturable, scalable realities.

Job Requirements

Novel Process Invention for Connector Fabrication

• Invent and prototype new manufacturing process sequences by creatively combining or re-sequencing established methods (e.g., laser ablation + selective plating, micro-stamping + laser trimming) to achieve connector geometries previously unattainable through conventional means.
• Identify known industrial or cross-industry processes and evaluate their applicability to connector and connector component manufacturing — adapting parameters, tooling, and sequencing as needed for high-precision outcomes.
• Develop process innovations specifically targeted at connector-relevant features: contact interfaces, terminal geometries, insulator micro-apertures, shielding structures, and fine-pitch lead frames.
• Establish novel fixturing, alignment, and in-process metrology strategies that enable repeatable, high-yield prototypes of miniaturized connector components.

Process Re-Deployment & Adaptation

• Systematically survey and evaluate mature manufacturing processes — including CNC micro-milling, wire EDM, femtosecond laser processing, ceramic injection molding, and thin-film deposition — and re-deploy them in novel configurations to address unmet connector performance or form-factor requirements.
• Design and execute structured DOE studies to characterize how re-purposed or hybridized processes interact with connector-critical materials (copper alloys, high-performance polymers, ceramics, composites, and thin-film conductors).
• Translate experimental findings into robust, documented process recipes, capability baselines (Cp/Cpk), and scalable work instructions tailored to connector component manufacturing.

Connector-Focused Innovation & Roadmap Development

• Collaborate with the Advanced Solutions Team (AST), Product Engineering, and Advanced Development (AD) to identify connector technology gaps where novel process invention can unlock new product capabilities — such as higher contact density, reduced insertion loss, improved mechanical retention, or novel termination methods.
• Act as the innovation bridge between connector design intent and manufacturing feasibility — proactively proposing process alternatives when conventional approaches constrain connector performance.
• Apply deep expertise in manufacturing technologies to develop application-specific connector manufacturing processes.
• Contribute to long-range capability roadmaps that position TE's Advanced Development organization as a leader in connector process innovation.

Cross-Functional Leadership & Knowledge Transfer

• Partner with AMP subject-matter experts, tooling engineers, and materials scientists to co-develop process innovations that span the full SPAM (Stamping, Plating, Assembly, Molding) value chain for connector components.
• Provide technical mentorship and hands-on training to engineers and technicians on novel process methodologies, equipment operation, and connector-specific manufacturing fundamentals.
• Work independently with broad latitude to define project objectives, select technical approaches, and deliver measurable innovation outcomes aligned with business unit connector strategies.

What your background should look like

• Minimum 8+ years of demonstrated R&D connector or hardware industry experience in manufacturing process development.
• Bachelor's Degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, or related discipline required or a minimum of 15+ years of equivalent experience will be considered.
• Experience with connector manufacturing environments involving Stamping, Plating, Assembly, and Molding (SPAM) technologies.
• Proficiency in CAD tools such as Creo, SolidWorks, or SpaceClaim or equivalent for connector compone