Mfg & Process Dvl Engineer

Job Title:

STAFF MFG & PROCESS DVL ENGINEER

At TE, you will unleash your potential working with people from diverse backgrounds and industries to create a safer, sustainable and more connected world.

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.

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

In this hands‑on leadership role, you will drive the design, optimization, and continuous improvement of manufacturing processes for precision electrical connectors used in aerospace and defense applications. You’ll work closely with production, tooling, quality, and maintenance teams to ensure robust, efficient, and cost‑effective operations.

This role directly supports advanced manufacturing technologies including manual and automated contact insertion, crimping, impact cold forming, pressing, and bonding — making it ideal for an engineer experienced in connector assembly and high‑reliability production environments.

Process Development:

• Design and iterate 3D printed models and manufacturing workflows.
• Develop and validate post‑processing methods for optimum performance.
• Optimize designs for additive manufacturing (DfAM) to reduce cost and improve reliability.

Production Support:

• Operate and maintain industrial 3D printers (DLP, FDM) and supporting equipment.
• Troubleshoot printing and assembly issues, ensuring smooth integration into production lines.

Quality Assurance:

• Perform dimensional inspections using CMM, optical comparators, and 3D scanning equipment.
• Implement strict quality protocols and document processes for compliance.

Collaboration:

• Work closely with R&D, product development, and supply chain teams to meet project goals.
• Communicate effectively with cross‑functional teams and customers.

Innovation:

• Stay updated on emerging additive manufacturing technologies and materials.
• Identify opportunities for process improvement and cost reduction.
• Support design‑for‑manufacturing (DFM) efforts during new product introduction.
• Lead root‑cause analysis and implement corrective actions for process deviations and nonconformances.
• Collaborate with maintenance and tooling teams to ensure equipment reliability and technical readiness.
• Prepare business cases and cost‑benefit analyses to justify new capital investments, ensuring alignment with ROI targets, operational strategy, and capacity planning.
• Justify, specify, and support the installation of new capital equipment to advance manufacturing capabilities.

• Due to ITAR regulations, US citizenship or US lawful permanent residency (green card) is required to apply for this position.
• Bachelor’s degree in Mechanical, Manufacturing, or Industrial Engineering (or related technical discipline).
  • 8+ years of manufacturing or design/development engineering experience.
  • Strong background in various 3D printing technologies.
  • Understanding of GD&T and ability to interpret engineering drawings.
  • Advanced expertise in CAD modeling and design (Creo or Solid Works or Space Claim), including the creation of tooling, fixtures, and detailed manufacturing layouts.
  • Understanding of Lean Manufacturing, Six Sigma, and SPC.
  • Strong analytical, problem‑solving, and communication skills with a focus on cross‑functional collaboration.
  • Ability to lead complex projects independently and mentor junior engineers or technicians.
  • Technical writing skills for process documentation and reports.
  • Strong written and verbal communication skills.

Please note :
This position may involve working with technical data, technology, software/source code, hardware or other items (collectively “items”)…