Senior Development Engineer- Advanced Joint and Bonding

Amphenol Communications Solutions; Nashua (NH); On-site; USD 120,000 - 180,000; Full time

Job summary

Amphenol Communications Solutions (ACS), a division of Amphenol Corporation, seeks a Sr. Technology Development Engineer to advance advanced joints and bonding technologies.

The role supports Nashua, NH and Hamden, CT locations, leading evaluation and implementation of ultrasonic, laser, thermal bonding, and related joining methods. Requirements include 5+ years in joining/assembly, DOE experience, and strong data-analysis skills.

Qualifications

• Requires 5+ years of experience in joining technologies or multi-material assembly processes (e.g., welding, thermal bonding, sealing, forming, or interconnect systems).
• Hands-on experience with ultrasonic, laser, thermal bonding, induction sealing, and mechanical joining.
• Experience designing and executing DOE, thermal cycling, accelerated aging, and mechanical/interface testing.
• Familiarity with mechanical testing (peel, shear, tensile) and validation methods.
• Ability to communicate technical findings to engineering and non-technical stakeholders.

Responsibilities

• Identify, evaluate, and select optimal joining solutions using ultrasonic, laser, thermal bonding, induction sealing, and mechanical joining.
• Lead trade studies and data-driven decisions on performance, reliability, manufacturability, and cost.
• Own system-level interface performance including root-cause analysis and validation programs (DOE, cycling, aging).
• Translate joining concepts into scalable manufacturing processes with process windows and bonding parameters.
• Collaborate with suppliers and cross-functional teams to implement joining technologies in production environments.

Skills

Ultrasonic welding

Laser welding

Thermal bonding

Induction sealing

Mechanical joining

DOE

Data analysis tools

MS Excel

Matlab

Minitab

Origin

Education

Master's or PhD 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.

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

Position Summary: Sr. Technology Development Engineer Advanced Joints and Bonding Engineer

Location: Hamden, CT or Nashua, NH

Responsibilities

• 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 Corporation is proud of our reputation as an excellent employer. Our focus is to provide the highest level of support and responsiveness to both our employees and our customers, the world's largest technology companies. Amphenol Corporation offers the opportunity for career growth within a global organization. We believe that Amphenol Corporation is unique in that every employee, regardless of his or her position, has the ability to positively impact the business.

Amphenol is an "Equal Opportunity Employer" - Minority/Female/Disabled/Veteran/Sexual Orientation/Gender Identity/National Origin. For additional company information please visit our website at https://www.amphenol-cs.com/