Senior Staff Engineer - 3D Tolerance Analysis & Dimensional Management

TE Connectivity India Pvt Ltd; Bengaluru; On-site; INR 3,000,000 - 5,400,000; Full time

Job summary

TE Connectivity India Pvt Ltd seeks a Staff Engineer for 3D tolerance analysis and dimensional management to lead predictive dimensional methods in data center/interconnect applications.

You will act as the COE expert in GD&T, participate with cross-functional teams, and mentor engineers to advance scalable 3D variation analyses and automation, aligning product design with manufacturing capabilities.

Qualifications

• Bachelor’s or master’s degree in mechanical engineering, manufacturing engineering, mechatronics, or related discipline.
• Typically 8+ years of relevant engineering experience.
• Expertise in 3D tolerance analysis, GD&T/ASME Y14.5, datum structures, assembly variation, and dimensional measurement.
• Proficiency with 3DCS, CETOL 6σ, or equivalent tools with worst-case, RSS, statistical, Monte Carlo, and sensitivity methods.
• Demonstrated success developing engineering methods, workflows, standards, or technical capabilities and leading complex cross-functional problem solving.

Responsibilities

• Lead complex 3D tolerance stack-up and variation analyses for precision interconnect products and assemblies.
• Resolve dimensional issues involving mating alignment, contact engagement, positional accuracy, interference, clearance, datum structures, and assembly sequence.
• Apply worst-case, RSS, statistical, Monte Carlo, and sensitivity methods to identify dominant risk contributors and improve design robustness.
• Support high-complexity design challenges where conventional 1D or manual stack-ups are insufficient.
• Partner with product, manufacturing, tooling, quality, metrology, reliability, and simulation teams from concept through qualification and root-cause investigation.
• Mentor engineers, lead workshops and design reviews, and build a dimensional-engineering community of practice.

Skills

3D tolerance analysis

GD&T

dimensional measurement

Education

Bachelor’s or Master’s in Mechanical/Manufacturing/Mechatronics

Tools

3DCS

CETOL 6σ

Job description

STAFF R&D/PRODUCT 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.

Job Overview

The Staff Engineer – 3D Tolerance Analysis & Dimensional Management is a technical leader within the Mechanical Engineering Center of Excellence (COE), supporting electrical interconnect products for data center and AI infrastructure applications. This role develops and deploys predictive 3D variation-analysis capabilities, serves as the subject matter expert in GD&T, statistical tolerance methods, and dimensional management, and helps product teams identify and mitigate dimensional risks early in development.

Job Requirements

• Lead complex 3D tolerance stack-up and variation analyses for precision interconnect products and assemblies.
• Resolve dimensional issues involving mating alignment, contact engagement, positional accuracy, interference, clearance, gaps, datum structures, and assembly sequence.
• Apply worst-case, RSS, statistical, Monte Carlo, and sensitivity methods to identify dominant risk contributors and improve design robustness.
• Support high-complexity design challenges where conventional 1D or manual stack-ups are insufficient.

Methods, Tools & Capability Development

• Develop scalable 3D dimensional-analysis methods, workflows, templates, libraries, and automation.
• Evaluate and benchmark tools such as 3DCS, CETOL 6σ, or equivalent technologies for accuracy, usability, CAD integration, and scalability.
• Translate functional and manufacturing inputs into predictive variation models, incorporating process capability, assembly variation, and measurement data.
• Verify models using prototype and production data and integrate with FEA, contact mechanics, optimization, or statistical methods where valuable.
• Identify capability gaps and recommend tool deployment, complementary methods, automation, and future investments.

GD&T, Standards & Dimensional Management

• Serve as the COE expert in GD&T, ASME Y14.5, datum strategy, tolerance schemes, and dimensional management.
• Connect functional requirements to dimensional requirements, 3D variation analysis, GD&T/PMI, manufacturing, and measurement.
• Balance product performance, manufacturing capability, quality, and cost when defining tolerance strategies.
• Create standards, quality criteria, templates, reference problems, and guidance for CTF/CTQ characteristics and method selection.

Technical Consulting & Leadership

• Partner with product, manufacturing, tooling, quality, metrology, reliability, and simulation teams from concept through qualification and root-cause investigation.
• Use process capability and CMM, optical metrology, CT, or other measurement data to correlate predicted and actual variation.
• Communicate findings as clear, actionable design recommendations.
• Mentor engineers, lead workshops and design reviews, and build a dimensional-engineering community of practice.

Mandatory Skills

• Required Bachelor’s or master’s degree in mechanical engineering, Manufacturing Engineering, Mechatronics, or a related discipline.
• Typically, 8+ years of relevant engineering experience.
• Expertise in 3D tolerance analysis, GD&T/ASME Y14.5, datum structures, assembly variation, and dimensional measurement.
• Proficiency with 3DCS, CETOL 6σ, or equivalent tools and with worst-case, RSS, statistical, Monte Carlo, sensitivity, and process-capability methods.
• Demonstrated success developing engineering methods, workflows, standards, or technical capabilities and leading complex cross-functional problem solving.

Preferred Experience

• Experience with precision electromechanical products such as electrical connectors, high-speed interconnects, cable assemblies, sockets, or electronics packaging.
• Experience in data center, AI infrastructure, networking, server, storage, or high-performance-computing applications.
• Experience benchmarking simulation tools; integrating tolerance analysis with FEA, contact mechanics, or optimization; using dimensional metrology; or developing engineering automation.

Role Focus

This is a COE capability-development and technical-expert role, focused on advancing methods and tools, solving high-complexity dimensional problems, establishing best practices, and enabling product teams to apply predictive dimensional management earlier in product development.

Experience Level

Senior Level