Senior Press-Fit Connector Design & Validation Engineer

Job Title: Senior Press-Fit Connector Design & Validation Engineer
Company: Intellectt INC
Location: Newark, CA
Experience: 8+ years
Pay Range: $50 - $55 per hr /On W2 / Contract

Job Summary

We are seeking a Senior Press-Fit Connector Design & Validation Engineer with expertise in electrical connectors, compliant-pin technology, and printed circuit board assembly (PCBA) interfaces. The engineer will investigate connector failures, improve press-fit pin designs, lead validation and reliability testing, and manage supplier technical deliverables for automotive power modules, including IGBT and SiC inverter applications.

Key Responsibilities

• Lead root-cause investigations into press-fit terminal failures, including pin push-out, PCB hole damage, fretting, and intermittent electrical connections.
• Review and improve Eye-of-Needle compliant-pin geometry, materials, plating, and press-fit characteristics.
• Define PCB-to-connector interface requirements to ensure proper fit, retention, and reliable electrical contact.
• Develop Design Verification Plans and Reports (DVP&R) and oversee insertion-force, push-out-force, thermal-cycling, vibration, and contact-resistance testing.
• Lead supplier technical discussions, drive 8D corrective actions, and verify design improvements.
• Review DFMEA, PFMEA, engineering drawings, and qualification reports.
• Coordinate prototype builds, sample testing, engineering changes (ECN/ECO), and PPAP activities.
• Perform or review nonlinear finite element analysis, modal analysis, and random vibration analysis using ANSYS or Abaqus.
• Collaborate with design, manufacturing, quality, and supplier teams to resolve technical issues and improve connector reliability.

Required Qualifications

• Bachelor's degree in Mechanical, Electrical, or Materials Engineering.
• At least 8 years of experience in connector design, electrical interconnects, or PCBA mechanical engineering.
• Hands-on experience with press-fit/compliant-pin technology, particularly Eye-of-Needle designs.
• Experience in automotive connector design, validation, and reliability testing.
• Strong understanding of PCBA interface design, PCB hole requirements, pin retention, and electrical contact performance.
• Knowledge of IEC 60352-5 and IPC-9797 standards.
• Experience with RCA, 8D corrective actions, DVP&R, DFMEA, and PFMEA.
• Experience managing supplier technical deliverables, engineering changes, and PPAP documentation.
• Experience performing or reviewing structural and vibration analysis using ANSYS or Abaqus.

Preferred Qualifications

• Experience working with automotive OEMs or electrical connector manufacturers.
• Experience with automotive power modules, IGBT modules, or SiC inverters.
• Experience resolving connector reliability issues from prototype development through production.

Benefits: Employees hired into this position are eligible for the following benefits, subject to the applicable plan terms and eligibility requirements
Health Insurance: Medical, dental, and vision insurance options are available through a third-party provider. Employees are responsible for paying the full cost of their insurance premiums.
Retirement Benefits: A 401(k) retirement savings plan is available. No employer matching or other employer contributions are provided.
Paid Time Off (PTO): No PTO other than that required by applicable state and local laws
Equal Employment Opportunity: Intellectt Inc. is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, sex, pregnancy, sexual orientation, gender identity, national origin, age, disability, genetic information, veteran status, or any other characteristic protected by applicable federal, state, or local law.

Thanks & Regards,
Mahalakshmi
Junior Recruiter
Intellectt Inc

mahalakshmi.n@intellectt.com