Senior Structural & Thermal FEA Engineer — Remote

TE Connectivity Ltd.; United States; On-site; USD 158,000 - 198,000; Full time

Benefits offered by this job

Health benefits

401(k)

Disability insurance

Life insurance

Employee stock purchase plan

Paid time off

Job summary

TE Connectivity seeks a Principal R&D/Product DVL Engineer to lead first-principles FEA and multi-physics simulations for next-gen high-speed interconnects. You will drive design decisions and partner with Signal Integrity, Mechanical Design, PDE/NPI to advance virtual prototyping.

Requires 8–10+ years in high-fidelity analysis, expertise with Ansys, Creo/SpaceClaim, and cloud HPC; strong communication for executive-level presentations essential.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Materials Science, or related field; Master’s or Ph.D. preferred.
• 8–10+ years of progressive engineering experience in high-fidelity FEA and structural/thermal-mechanical analysis in high-tech electromechanical products, connectors, high-speed interconnects, or electronic packaging.
• Expert in commercial FEA platforms (Ansys preferred) with mastery in non-linear materials, complex contact interfaces, and thermal-stress coupling.
• Strong test correlation and model calibration experience (strain gauges, displacement/force measurements, thermal warpage).
• Deep understanding of high-speed interconnect architectures, micro-contact physics, spring pin design, socket/cable assemblies, and CTE management in AI/compute hardware environments.
• Proficiency with 3D CAD tools (Creo/SpaceClaim) for defeaturing, parameterization, and simulation prep.
• Experience with cloud/HPC simulation environments and automation scripting (Python, MATLAB).
• Ability to communicate complex results to cross-functional teams and leadership.

Responsibilities

• Lead first-principles engineering analysis, FEA modeling, and multi-physics simulation to down-select concepts.
• Develop reduced-order mechanical/thermal models to screen early architectures and identify scaling limits.
• Execute high-fidelity nonlinear structural and thermal-mechanical simulations (elastoplastic, creep, stress relaxation, CTE, contact).
• Perform sensitivity studies, tolerance stack-ups, and statistical variation analyses for assembly robustness.
• Define simulation-ready geometry, boundaries, and loading with GD&T guidance.
• Handle large FEA models with hundreds of components; balance accuracy with efficiency.
• Deliver comprehensive simulation reports, design recommendations, and presentations to senior leadership.
• Lead physical prototype test plans and coordinate V&V to correlate with simulations.
• Ensure smooth handoff of validated models to PDE/NPI teams for commercialization.
• Drive automation of simulation processes and scripting; advance virtual prototyping methods.
• Maintain awareness of HPC, new materials, and packaging/interconnect technologies.

Skills

FEA

Multi-physics

Ansys Mechanical

Non-linear analysis

Python

MATLAB

Creo

SpaceClaim

Rescale

High-performance computing

Model validation

Education

Bachelor-level degree in Mechanical Engineering or related field

MS or PhD strongly preferred

Tools

Ansys

Creo

SpaceClaim

Rescale

Python

MATLAB

Job description

TE Connectivity seeks a Principal R&D/Product DVL Engineer to lead first-principles FEA and multi-physics simulations for next-gen high-speed interconnects. You will drive design decisions and partner with Signal Integrity, Mechanical Design, PDE/NPI to advance virtual prototyping.

Requires 8–10+ years in high-fidelity analysis, expertise with Ansys, Creo/SpaceClaim, and cloud HPC; strong communication for executive-level presentations essential.