Staff Engineer - Product Development (Contact Systems)

Job Summary:

Amphenol Power Solutions 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.

The ideal candidate will be a strategic technical leader with a strong background in mechanical and electro-mechanical design, including power connector architecture, contact system design, sealing, and cable interface solutions, with a proven ability to drive cross-functional collaboration and mentor engineering talent.

Responsibilities:

Technical Leadership

· 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.

Product Development & Execution

· 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.

Process, Collaboration & Strategy

· 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.

Required Qualifications:

· 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:

o Contact systems (high current, low resistance, plating, wear)

o Sealing systems (IP-rated connectors, gaskets, environmental protection)

o 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.

Behavioral Competencies:

· Performance Focused: Executes efficiently, meeting project deadlines and deliverables.

· Creative Thinker: Brings innovative, long-term solutions to technical challenges.

· Coach: Capable of mentoring others and leading technical project teams.

· Up to 25% travel domestically and internationally.

Why Join Us?

At Amphenol Power Solutions, you’ll play a key role in shaping the future of power connectivity and innovation. We offer a collaborative and inclusive culture, opportunities for global exposure, and a chance to make a real impact on products that power the world.