Senior Mechanical Design Engineer - Electronic Components; Mil​/Def​/Aero Connector Systems

Senior Mechanical Design Engineer - Electronic Components (Mil/Def/Aero Connector Systems)

As a Senior Mechanical Design Engineer, you will lead the mechanical design and development of Aerospace and Defense electronic components and connector systems from concept through production and field support. You will set technical direction, drive design-for-manufacturing and design-for-reliability practices, and ensure solutions meet functional, performance, cost, schedule, and quality targets. You will work cross-functionally with R&D, manufacturing, quality, procurement, and customers and serve as a technical mentor for the engineering team.

You will join a high-performing engineering division focused on innovation in connector systems and electronic components. The team combines expertise in mechanical design, materials, manufacturing, and quality assurance to deliver robust, cost-effective solutions for demanding applications and customers.

Lead feasibility studies and technical assessments for customer proposals and new product initiatives; define technical requirements and success criteria.

Architect and develop connector systems and electronic components using customer input, product specifications, test data, and engineering best practices.

Produce and approve detailed 3D models, assemblies, and manufacturing drawings; apply GD&T for critical dimensions and tolerances.

Lead prototype development, integration, and validation testing (environmental, mechanical, electrical interface, reliability); define test plans and acceptance criteria.

Use CAE tools (FEA, thermal, vibration) to analyze and optimize designs for strength, stiffness, fatigue life, and thermal performance.

Drive DFMEA/PFMEA activities and implement risk mitigation strategies; own corrective actions for field and production issues.

Define and optimize manufacturing processes (injection molding, stamping, forming, plating, assembly) and design required tooling, fixtures, and gauge systems.

Lead vendor selection and technical collaboration with suppliers to ensure component manufacturability, cost targets, and quality expectations.

Manage projects end-to-end, including schedules, budgets, design reviews, and status reporting; ensure on-time delivery to program milestones.

Mentor and coach junior engineers; lead design reviews and promote continuous improvement in methods and processes.

Support product launches, transfer to production, and post-launch sustainment including troubleshooting and cost reduction efforts.

Ensure compliance with applicable industry standards and regulations (e.g., RoHS, REACH, relevant connector/IPC/UL/MIL standards as applicable).

Contribute to intellectual property generation (patents, trade secrets) and maintain thorough engineering documentation and BOMs.

Bachelor's degree in Mechanical Engineering, Mechanical Engineering Technology, or related engineering field from an accredited institution. Master's degree preferred.

5+ years of relevant experience in mechanical design of electronic components, connectors, or interconnect systems (or equivalent combination of education and experience).

Proficient with 3D CAD (Solid Works, Creo, or equivalent) and experience with CAD best practices for complex assemblies.

Practical experience with CAE tools (e.g., FEA, thermal analysis) and interpreting results to inform design decisions.

Strong understanding of GD&T, tolerance analysis, materials selection, and manufacturing processes for electronic components.

Proven ability to read and interpret technical documents, engineering drawings, and industry standards.

Excellent written and verbal communication skills; comfortable presenting technical concepts to diverse stakeholders.

Strong analytical and problem-solving skills; capable of driving design decisions using data and test results.

Direct experience designing connector systems and demonstrated knowledge of connector interfaces, plating, contact materials, and mating cycles.

Experience with reliability testing and environmental qualifications (HALT, HASS, vibration, thermal cycling).

Experience leading DFMEA, DFM/DFMA activities, and cost reduction programs.

Experience with product lifecycle management (PLM) systems and configuration control. Using Wind Chill and overseeing Engineering Changes is a plus.

Prior experience managing cross-functional technical teams and mentoring junior engineers through a product development stage gate process.

Certifications such as PE (Professional Engineer), PMP, Six Sigma (Green/Black Belt), or equivalent are a plus.

Familiarity with regulatory standards relevant to target markets (e.g., IEC, UL, MIL specs when relevant).

Willingness to travel domestically or internationally up to 10–20% (if required).

Time-to-market vs. program schedule

Design cost reduction / target cost achievement

Number of field issues per product-family (quality KPI)

On-time delivery of design milestones

Mentor/employee development outcomes