Staff Mfg & Process Dvl Engineer

Company Overview

TE Connectivity Ltd. is a $16 billion global technology and manufacturing leader committed to creating a safer, sustainable, productive, and connected future. For over 75 years, our connectivity and sensor solutions have enabled advancements across transportation, industrial applications, medical technology, energy, data communications, and the home.

With 90,000 employees, including more than 8,000 engineers, in nearly 140 countries, TE ensures that Every Connection Counts. Learn more at www.te.com and follow TE Connectivity on LinkedIn, Facebook, WeChat, and Twitter.

About Aerospace, Defense & Marine (AD&M)

TE’s Aerospace, Defense & Marine (AD&M) business unit, part of our Industrial Solutions segment, is a global leader in designing high-performance electrical interconnect solutions for the world’s most demanding environments.

Our technologies enable critical applications, from avionics, propulsion systems, and flight controls to naval vessels, ground vehicles, and space exploration. From the ocean’s depths to the edge of space, TE delivers reliable connectivity that performs in the harshest conditions on Earth.

Job Overview

TE Connectivity’s Aerospace, Defense & Marine (AD&M) division is seeking an experienced Staff Mechanical Design Engineer to join our team in Mount Joy, PA.

In this hands-on technical leadership role, you will lead the mechanical design and development of manufacturing equipment, tooling, fixtures, mechanisms, and automation systems supporting precision electrical connector manufacturing.

The position will take mechanical concepts from initial requirements through 3D CAD design, engineering analysis, tolerance development, detailed drawings, prototype/build, design verification, installation, and production release. The engineer will work closely with manufacturing, tooling, controls, maintenance, quality, and production teams to develop robust mechanical solutions for demanding, high-reliability manufacturing applications.

The role will support equipment and tooling associated with processes central to the operation, including contact insertion, crimping, impact cold forming, pressing, bonding, and automated assembly.

Key Responsibilities

• Lead the mechanical design and development of custom manufacturing equipment, tooling, fixtures, dies, and automated assembly systems.


• Develop mechanical concepts and take designs from concept through detailed design, build, debugging, validation, and production release.


• Create and maintain 3D CAD models, assemblies, detailed engineering drawings, and Bills of Material (BOMs).


• Apply GD&T and tolerance analysis to ensure repeatable assembly, interchangeability, manufacturability, and equipment performance.


• Perform engineering calculations supporting loads, stresses, deflection, fits, fastening, actuation, component sizing, and structural integrity.


• Design mechanisms, machine frames, guarding, nests, workholding, press tooling, insertion tooling, and precision locating systems.


• Specify mechanical components including linear motion systems, bearings, actuators, pneumatic components, motors, gearboxes, sensors, and machine elements.


• Conduct and lead mechanical design reviews, including review of concepts, drawings, tolerance schemes, safety considerations, maintainability, and manufacturing feasibility.


• Apply DFM/DFA principles to both production equipment and new product introduction.


• Work directly with internal and external machine builders, toolmakers, vendors, and suppliers.


• Troubleshoot mechanical equipment and tooling issues using structured root-cause analysis and engineering fundamentals.


• Improve existing machinery through mechanical redesign, tooling upgrades, error proofing, reliability improvements, and cycle-time optimization.


• Develop technical specifications and acceptance criteria for new tooling and capital equipment.


• Provide technical leadership and mentor engineers, designers, and engineering technicians.


• Prepare technical justification and business cases for capital equipment and mechanical system investments, including cost, capacity, technical risk, and ROI.


• Support manufacturing processes such as pressing, impacting, crimping, contact insertion, and automated connector assembly.

Qualifications

• Bachelor’s degree in Mechanical Engineering or a closely related engineering discipline.


• 5–7+ years of experience in mechanical design, machine design, tooling design, manufacturing equipment development, or automation equipment design.


• Advanced proficiency in Creo or SolidWorks, including complex part modeling, assemblies, configurations, and production drawings.


• Strong knowledge of GD&T, engineering drawings, tolerance stack-up analysis, fits, materials, fasteners, and mechanical design practices.


• Demonstrated experience designing tooling, fixtures, mechanisms, production machinery, or automated manufacturing equipment.


• Strong understanding of mechanical engineering fundamentals, including statics, dynamics, strength of materials, machine design, and material selection.


• Experience designing equipment incorporating pneumatic, servo, robotic, vision, or other automated systems is preferred.


• Programming and electrical controls experience, including PLCs, HMIs, machine controls, or industrial automation integration, is a plus.


• Six Sigma Black Belt certification is a plus.


• Experience with precision assembly, stamping, metal forming, pressing, crimping, or electrical connector manufacturing is highly desirable.


• Ability to independently lead technically complex projects from requirements definition through design, build, qualification, and production implementation.


• Experience interacting with machine shops, toolmakers, equipment builders, and component suppliers.


• Working knowledge of DFMEA/PFMEA, root-cause analysis, and equipment/process validation.


• Ability to develop technical requirements and support capital equipment justification and procurement.


• Strong problem-solving, project leadership, and technical communication skills.


• Ability to mentor junior engineers, designers, and technicians.

Core Competencies

• Mechanical Design Excellence


• Machine & Tooling Design


• Engineering Analysis & Problem Solving


• Design for Manufacturing & Assembly


• Technical Project Leadership


• Hands-On Engineering


• Innovation & Continuous Improvement


• Cross-Functional Collaboration