Sr R&D​/Product Dvl Engineer

Senior Mechanical Engineer

Join TE Connectivity's innovative Passive Optics organization as a Senior Mechanical Engineer and help design the next generation of precision optical connector systems powering AI and hyperscale computing infrastructure. You'll solve complex mechanical engineering challenges in sub-micron precision design, working with advanced materials to create products that enable the world's most demanding optical interconnect applications.

As AI workloads demand unprecedented reliability and performance, precision mechanical design of optical connectors has become mission-critical. You'll be at the forefront of solving complex mechanical challenges involving metals, plastics, and innovative latching mechanisms that directly enable the optical revolution while advancing TE's leadership in high-performance connectivity solutions.

Operations are currently based at a temporary site in Webster, NY. The team will transition to a permanent Rochester location (near RIC) upon completion.

Job Requirements:

• Connector System Architecture:
  Design innovative passive optical connector assemblies with sub-micron alignment precision for fiber-to-PIC (Photonic Integrated Circuit) applications
• Tolerance Engineering:
  Develop sub-micron tolerance control strategies ensuring optimal mechanical and optical performance across temperature ranges and environmental conditions
• Performance Optimization:
  Engineer solutions for critical mechanical parameters including connector durability, insertion/withdrawal forces, and long-term stability
• Materials Selection:
  Evaluate and specify advanced metals and engineering plastics for precision optical connector applications with focus on dimensional stability and wear resistance
• Compliant Structures:
  Design innovative compliant mechanisms for connector alignment, engagement, and stress relief while maintaining optical precision
• Mechanical Validation:
  Design and execute comprehensive test protocols for static and dynamic loading, fatigue resistance, and environmental stress validation
• Latching Mechanisms:
  Develop innovative latching and retention systems optimized for connector reliability, user experience, and manufacturing efficiency
• Strain Relief Design:
  Engineer strain relief solutions that protect fiber optics under mechanical stress while maintaining connector alignment precision
• Load Analysis:
  Perform static and dynamic stress analysis on connector assemblies, including finite element modeling of complex loading scenarios
• Precision Assembly:
  Design connector systems for automated assembly processes while maintaining sub-micron alignment tolerances
• Prototyping:
  Lead rapid prototyping efforts from concept through production-ready mechanical designs using advanced manufacturing techniques
• Testing & Characterization:
  Develop comprehensive mechanical test methodologies for connector performance, durability, and manufacturing quality control
• Cross-functional Collaboration:
  
  Work closely with optical engineering, manufacturing, and quality teams to ensure design for manufacturability (DFM) and optical performance

Essential

Qualifications:

• Education:
  
  BS/MS in Mechanical Engineering, Materials Science, or related technical field
• Experience:
  
  a minimum of 5 years in precision mechanical design, preferably in connector or optical systems; or 3 years and a Master's degree; or a PhD without work experience
• Materials Expertise:
  Hands-on experience with metals and engineering plastics in precision applications
• Design Tools:
  Proficiency with 3D CAD software (Solid Works, NX, Creo) and finite element analysis tools

Core Technical

Competencies:

• Precision Engineering:
  Deep understanding of sub-micron tolerancing, statistical tolerance analysis, and precision manufacturing processes
• Structural Mechanics:
  Experience with compliant structures, spring mechanisms, and dynamic loading analysis of small-scale mechanical systems
• Materials Science:
  Understanding of material properties, thermal expansion, creep, and long-term stability of metals and polymers
• Testing & Validation:
  Proficiency with mechanical test equipment, load testing, and statistical quality control methods

Specialized Knowledge Areas:

• Connector Design:
  Experience with latching mechanisms, strain relief systems, and connector assembly processes
• Static/Dynamic Analysis:
  Expertise in stress analysis, fatigue life prediction, and mechanical reliability engineering
• Manufacturing Processes:
  Knowledge of injection molding, precision machining, and assembly automation for small-scale components
• Quality Systems:
  Understanding of tolerance control, process capability studies, and Design for Six Sigma methodologies

Professional

Skills:

• Problem Solving:
  Creative approach to complex mechanical design challenges with systematic engineering methodology
• Communication:
  Ability to present technical concepts to cross-functional teams and document detailed mechanical specifications
• Project Management:
  Experience managing multiple development projects with competing priorities and tight…