Senior Development Engineer- Advanced Joint and Bonding

Amphenol ICC; Hamden (CT); On-site; USD 120,000 - 170,000; Full time

Job summary

Amphenol Communications Solutions (ACS), a division of Amphenol Corporation, seeks a Senior Development Engineer to lead advanced joining and bonding technologies for multi-material interconnect constructions. You will select and implement ultrasonic, laser, thermal bonding, induction sealing, and mechanical joining methods, with focus on reliability and scalable manufacturing.

The role requires 5+ years in joining or multi-material assembly, and experience with DOE, thermal cycling, and

Qualifications

• Master's or Ph.D. in Mechanical or Industrial Engineering or related field.
• 5+ years of experience in joining technologies or multi-material assembly processes (welding, bonding, sealing, forming).
• Hands-on experience with ultrasonic, laser, thermal bonding, induction sealing, and mechanical joining.

Responsibilities

• Identify, evaluate, and select optimal joining solutions (ultrasonic, laser, thermal bonding, induction sealing, mechanical).
• Lead trade studies and technology down-selection based on performance and cost.
• Own system-level interface performance and run validation programs (DOE, thermal cycling, aging).
• Translate joining concepts into scalable manufacturing processes and parameters.
• Collaborate with suppliers and cross-functional teams to implement joining tech in production.

Skills

Joining technologies

Multi-material assembly

Data-driven decisions

Cross-functional communication

Data analysis

Education

Master's or Ph.D. in Mechanical/Industrial Engineering

Tools

MS Excel

MATLAB

Minitab

Origin

Job description

Amphenol Communications Solutions (ACS), a division of Amphenol Corporation, is a world leader in interconnect solutions for Communications, Mobile, RF, Optics, and Commercial electronics markets. Amphenol Corporation is one of the world’s largest designers and manufacturers of electrical, electronic and fiber optic connectors and interconnect systems, antennas, sensors and sensor-based products and coaxial and high-speed specialty cable. ACS has an expansive global presence in research and development, manufacturing, and sales. We design and manufacture a wide range of innovative connectors as well as cable assemblies for diverse applications including server, storage, data center, mobile, RF, networking, industrial, business equipment, and automotive.

Position Summary

Sr. Technology Development Engineer – Advanced Joints and Bonding Engineer

Location

Hamden, CT or Nashua, NH

Amphenol High Speed Products Group is the market leader for high speed, high bandwidth electrical connectors for the Telecom/Datacom market (Mobile Networks, Storage, Servers, Routers, Switches, etc.). Our products help to enable the electronics revolution and remain a key enabler for all the major Tier 1 OEM's globally. Our global headquarters are located in Nashua, NH and we have design, sales and manufacturing locations globally

We are currently seeking a Senior Development Engineer – Advanced Joint and Bonding to join the team.

Responsibilities

As Sr. Engineer of Joining and Bonding, you will own the selection, development, and implementation of joining technologies for multi-material interconnect constructions, including foils and overwrap systems.

• Identify, evaluate, and select optimal joining solutions leveraging technologies such as ultrasonic welding, laser welding, thermal bonding, induction sealing, and mechanical joining
• Lead trade studies and technology down-selection, making data-driven decisions based on performance, reliability, manufacturability, and cost
• Own system-level interface performance, including:
  • Root cause analysis of joint failures
  • Design and execution of validation programs (DOE, thermal cycling, accelerated aging, interface testing)
  • Development of robust solutions with proven high-temperature reliability margins
• Translate joining concepts into scalable manufacturing processes, including:
  • Process windows
  • Equipment and bonding parameters
  • Risk profiles and mitigation strategies
  • Scale-up and production readiness plans
• Collaborate with suppliers, manufacturing, and cross-functional teams to ensure successful implementation of joining technologies in production environments

Qualifications

• Master's or Ph.D. degree in Bachelor's, Master's, or Ph.D. degree in Mechanical Engineering, Industrial Engineering, or related field
• 5+ years of experience in joining technologies or multi-material assembly processes (e.g., welding, thermal bonding, sealing, forming, or interconnect systems; foil or overwrap experience preferred)
• Hands-on experience with multiple joining methods, including:
  • Ultrasonic welding
  • Laser welding
  • Thermal bonding / sealing
  • Induction sealing
  • Mechanical joining
• Demonstrated ability to:
  • Evaluate and select between joining technologies
  • Solve interface and assembly-level performance challenges
  • Drive data-based decisions under real-world manufacturing constraints
• Experience designing and executing:
  • DOE (Design of Experiments)
  • Thermal cycling and accelerated aging
  • Mechanical and interface testing
• Familiarity with:
  • Mechanical testing (peel, shear, tensile)
  • Thermal and process validation methods
• Ability to work cross-functionally and communicate technical findings to both engineering and non-technical stakeholders.
• Curiosity-driven mindset with a passion for innovation and emerging technologies
• Experience with data analysis software, MS Excel, Matlab, Minitab and/or Origin

Amphenol is an “Equal Opportunity Employer” - Minority/Female/Disabled/Veteran/Sexual Orientation/Gender Identity/National Origin.