Senior Mechanical Design Engineer - Electronic Components (Mil/Def/Aero Connector Systems)

Flint Hills Resources; Georgetown (TX); On-site; USD 90,000 - 140,000; Full time

Job summary

Molex, a Koch company, seeks a Senior Mechanical Design Engineer to lead the mechanical design and development of aerospace connector systems and electronic components from concept through production.

You will set technical direction, drive design-for-manufacturing/reliability, perform DFMEA, and collaborate with R&D, manufacturing, quality, procurement, and customers while mentoring the engineering team.

Qualifications

• Bachelor's degree in Mechanical Engineering; Master's preferred.
• 5+ years of mechanical design experience for electronic components/connectors.
• Proficient in 3D CAD and GD&T for complex assemblies.
• Experience with CAE tools and interpreting results for design decisions.
• Strong written/verbal communication and problem-solving skills.

Responsibilities

• Lead feasibility studies and define technical requirements for proposals.
• Architect and develop connector systems and electronic components per specs and test data.
• Create and approve 3D models, assemblies, and manufacturing drawings with GD&T.
• Lead prototype development, testing, and validation plans.
• Apply CAE tools to optimize strength, thermal, and reliability performance.
• Drive DFMEA/PFMEA and implement risk mitigation actions.
• Define manufacturing processes and tooling requirements.
• Lead supplier selection and cross-functional design reviews.
• Manage projects end-to-end with schedules and budgets.
• Mentor junior engineers and contribute to continuous improvement.

Skills

Mechanical design experience

3D CAD (SolidWorks/Creo)

CAe tools (FEA, thermal analysis)

GD&T and tolerancing

Communication/presentations

Education

Bachelor's degree in Mechanical Engineering

Master's degree preferred

Tools

WindChill PLM

PLM systems

Job description

Senior Mechanical Design Engineer - Electronic Components (Mil/Def/Aero Connector Systems)

In order to comply with U.S. export control laws and regulations, this position requires applicants to either provide proof of U.S. citizenship or lawful permanent resident status or be eligible to receive an export authorization (a license) under the International Traffic in Arms Regulations and/or the Export Administration Regulations.

Your Job

As a Senior Mechanical Design Engineer, you will lead the mechanical design and development of Aerospace and Defense electronic components and connector systems from concept through production and field support. You will set technical direction, drive design-for-manufacturing and design-for-reliability practices, and ensure solutions meet functional, performance, cost, schedule, and quality targets. You will work cross-functionally with R&D, manufacturing, quality, procurement, and customers and serve as a technical mentor for the engineering team.

Our Team

You will join a high-performing engineering division focused on innovation in connector systems and electronic components. The team combines expertise in mechanical design, materials, manufacturing, and quality assurance to deliver robust, cost-effective solutions for demanding applications and customers.

What You Will Do (Primary Responsibilities)

• Lead feasibility studies and technical assessments for customer proposals and new product initiatives; define technical requirements and success criteria.
• Architect and develop connector systems and electronic components using customer input, product specifications, test data, and engineering best practices.
• Produce and approve detailed 3D models, assemblies, and manufacturing drawings; apply GD&T for critical dimensions and tolerances.
• Lead prototype development, integration, and validation testing (environmental, mechanical, electrical interface, reliability); define test plans and acceptance criteria.
• Use CAE tools (FEA, thermal, vibration) to analyze and optimize designs for strength, stiffness, fatigue life, and thermal performance.
• Drive DFMEA/PFMEA activities and implement risk mitigation strategies; own corrective actions for field and production issues.
• Define and optimize manufacturing processes (injection molding, stamping, forming, plating, assembly) and design required tooling, fixtures, and gauge systems.
• Lead vendor selection and technical collaboration with suppliers to ensure component manufacturability, cost targets, and quality expectations.
• Manage projects end-to-end, including schedules, budgets, design reviews, and status reporting; ensure on-time delivery to program milestones.
• Mentor and coach junior engineers; lead design reviews and promote continuous improvement in methods and processes.
• Support product launches, transfer to production, and post-launch sustainment including troubleshooting and cost reduction efforts.
• Ensure compliance with applicable industry standards and regulations (e.g., RoHS, REACH, relevant connector/IPC/UL/MIL standards as applicable).
• Contribute to intellectual property generation (patents, trade secrets) and maintain thorough engineering documentation and BOMs.

Who You Are (Basic Qualifications)

• Bachelor’s degree in Mechanical Engineering, Mechanical Engineering Technology, or related engineering field from an accredited institution. Master’s degree preferred.
• 5+ years of relevant experience in mechanical design of electronic components, connectors, or interconnect systems (or equivalent combination of education and experience).
• Proficient with 3D CAD (SolidWorks, Creo, or equivalent) and experience with CAD best practices for complex assemblies.
• Practical experience with CAE tools (e.g., FEA, thermal analysis) and interpreting results to inform design decisions.
• Strong understanding of GD&T, tolerance analysis, materials selection, and manufacturing processes for electronic components.
• Proven ability to read and interpret technical documents, engineering drawings, and industry standards.
• Excellent written and verbal communication skills; comfortable presenting technical concepts to diverse stakeholders.
• Strong analytical and problem-solving skills; capable of driving design decisions using data and test results.

What Will Put You Ahead (Preferred Qualifications)

• Direct experience designing connector systems and demonstrated knowledge of connector interfaces, plating, contact materials, and mating cycles.
• Experience with reliability testing and environmental qualifications (HALT, HASS, vibration, thermal cycling).
• Experience leading DFMEA, DFM/DFMA activities, and cost reduction programs.
• Experience with product lifecycle management (PLM) systems and configuration control.Using WindChill and overseeing Engineering Changes is a plus.
• Prior experience managing cross-functional technical teams and mentoring junior engineers through a product development stage gate process.
• Certifications such as PE (Professional Engineer), PMP, Six Sigma (Green/Black Belt), or equivalent are a plus.
• Familiarity with regulatory standards relevant to target markets (e.g., IEC, UL, MIL specs when relevant).
• Willingness to travel domestically or internationally up to 10–20% (if required).

Success Metrics (Examples)

• Design cost reduction / target cost achievement
• Number of field issues per product-family (quality KPI)
• On-time delivery of design milestones

At Koch companies, we are entrepreneurs. This means we openly challenge the status quo, find new ways to create value and get rewarded for our individual contributions. Any compensation range provided for a role is an estimate determined by available market data. The actual amount may be higher or lower than the range provided considering each candidate's knowledge, skills, abilities, and geographic location. If you have questions, please speak to your recruiter about the flexibility and detail of our compensation philosophy.

Hiring Philosophy

All Koch companies value diversity of thought, perspectives, aptitudes, experiences, and backgrounds. We are Military Ready and Second Chance employers. Learn more about our hiring philosophy here .

Who We Are

As a Koch company, Molex is a leading supplier of connectors and interconnect components, driving innovation in electronics and supporting industries from automotive to health care and consumer to data communications. The thousands of innovators who work for Molex have made us a global electronics leader. Our experienced people, groundbreaking products and leading-edge technologies help us deliver a wider array of solutions to more markets than ever before.

At Koch, employees are empowered to do what they do best to make life better. Learn how our business philosophy helps employees unleash their potential while creating value for themselves and the company.

Our goal is for each employee, and their families, to live fulfilling and healthy lives. We provide essential resources and support to build and maintain physical, financial, and emotional strength - focusing on overall wellbeing so you can focus on what matters most. Our benefits plan includes - medical, dental, vision, flexible spending and health savings accounts, life insurance, ADD, disability, retirement, paid vacation/time off, educational assistance, and may also include infertility assistance, paid parental leave and adoption assistance. Specific eligibility criteria is set by the applicable Summary Plan Description, policy or guideline and benefits may vary by geographic region. If you have questions on what benefits apply to you, please speak to your recruiter.

Additionally, everyone has individual work and personal needs. We seek to enable the best work environment that helps you and the business work together to produce superior results.

Equal Opportunity Employer, including disability and protected veteran status. Except where prohibited by state law, some offers of employment are conditioned upon successfully passing a drug test. This employer uses E-Verify. Please click here for additional information. (For Illinois E-Verify information click here , aquí , or tu ).