Job Overview

The Data and Devices Business Unit is looking for a Staff R&D Product Development Engineer (PDE) to design and develop BBA (busbar assembly) solutions for AI data centers. In this role, you will be responsible for the design and documentation of new busbar assembly products from market definition through production release. You will conceive original ideas for new products and solutions and develop them into practical, reliable, manufacturable, and cost-effective designs. You will define specifications, perform engineering analyses, develop preliminary concepts and detailed designs, and coordinate engineering samples, testing, qualification, and production launch. Close interaction with customers, suppliers, manufacturing, quality, marketing, sales, and other engineering functions during all stages of product development is an important part of this role.

Job Requirements

• Responsible for the development of BBA (busbar assembly) products and solutions from market definition through production release:
  • Work closely with the customer and TE sales/SA/FAE/PM in getting the right and clear VOC (voice of customer) and convert to a TE design conceptualization and preliminary product specification.
  • Conceive concepts and perform feasibility studies.
  • Perform mechanical, structural, thermal, and electrical-thermal analyses for busbar assemblies, including temperature rise, current-carrying capability, insulation, clearances, and joint performance.
  • Make the engineering evaluation/proposal to the customer.
  • Create the detailed design including 2D/3D drawings and perform DFMEA/tolerance analysis.
  • Build prototype samples and perform validation.
  • Complete product qualification and finalize product specification.
  • Provide technical support to the Operations team including Quality and Production for efficiency improvement and safe launch.
  • Resolve product related issues to closure and manage the ECN/PCN (Engineering Change Notification/ Product Change Notification).
• Build a deep understanding of the market and customer needs by fostering a connection between the business engineering teams and the customer engineering teams.
• Maintain a system level understanding of the customer application and the product design/concept necessary for providing a solution to the customers’ expectation.
• Follow the LEANPD Project Process to support the project team from the product development engineering (PDE) perspective to complete the new product development project on time, quality and budget. Drive the development and release of product, scale-up through stage-gate reviews, ensuring milestone commitments are maintained.
• Provide technical support to customer, sales, PM and plant teams. Conduct necessary DFMEA, tests, engineering analysis, trouble shooting and verification.
• Work with global manufacturing resources, procurement, and outside suppliers to meet all TE technical, quality, and cost objectives.
• Provide technical training and hands-on guidance to the engineering team across molding, stamping, metal extrusion, machining, and welding processes; lead DFM reviews and drive continuous improvement of supplier manufacturing process capabilities.
• Execute technical documentation to fully detail design drawings and requirements, engineering and product change notices, and design history files.
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What your background should look like

• Bachelor’s degree in mechanical engineering or equivalent work experience.
• Minimum 10 years of relevant professional experience, including at least 5 years of hands-on mechanical design experience.
• Minimum 5 years of industry experience in one or more of the following sectors: AI data centers (AIDC), electrical equipment or systems, high-voltage electric vehicles (EV), or energy storage systems.
• Strong knowledge of busbar assembly design and development, including copper and aluminum conductor design, insulation systems, plating and surface finishes, electrical and mechanical interfaces, joining technologies, material selection, tolerance analysis, DFMEA, product qualification, and design for manufacturability.
• Expert in 3D CAD applications (Creo preferred) with experience in 3D solid modeling including sheet metal, 2-D drawings, PDM link Data Manager and general knowledge in design applications such as Spaceclaim, Creo or others used only in the concept stage.
• Proficient in geometric dimensioning & tolerancing (GD&T).
• Proficient at limit and fit analysis including statistical tolerance analysis.
• Proficient user of finite element analysis software (Ansys, Workbench) including elastic and plastic behavior of metals.
• Proficient in developing and writing design objectives for product specifications.
• Demonstrated proficiency in at least four of the following manufacturing processes: molding, stamping, metal extrusion, machining, plating and welding, with foundational knowledge of the remaining two. Proven ability to lead Design for Manufacturing (DFM) reviews, train and coach engineering teams, and improve supplier manufacturing process capabilities.
• Excellent English communication skills, both written and verbal, with the ability to lead technical discussions, deliver training, and communicate effectively with global teams, suppliers, and external customers.
• Ability to work in a global environment – able to accommodate varying time zones and capable of collaborating with individuals across geographies.
• This position is based in Shenzhen, China.
• Willingness and ability to travel approximately 20%–40% of the time, including domestic and international travel as business needs require.
• Advanced problem solver – able to handle moderate complexity situations and use data analytics and critical thinking to reach logical conclusions with limited direction.
• Proficient using MS office software (Word, Excel, PPT, Outlook, MS Teams, etc.).

Nice To Have Skills/Experience:

• Master’s degree in engineering or related field.
• Familiarity with AI server, rack power, power shelf, power distribution, high-voltage EV, or energy storage system architectures and their busbar interconnection requirements.
• Proficient use of quality tools (FMEA, 6 sigma, DOE, 8D, etc.).
• In-depth knowledge of busbar conductor materials, plating and surface-treatment systems, insulation materials, joint interfaces, fastening methods, welding processes, and corrosion and reliability considerations.
• General knowledge of electrical power distribution, current density, voltage drop, temperature rise, creepage and clearance, short-circuit withstand, and insulation coordination for busbar systems.
• Strong organizational and time management skills with an ability to manage and execute multiple tasks/deadlines/projects simultaneously with limited direction.
• Proficient in leading technical discussions in project teams.

Competencies