Senior Product Development Engineer

Position Overview

TS Conductor is seeking a Senior Product Development Engineer to develop, qualify, and support the hardware and stranding partnerships required for successful deployment of our advanced overhead transmission conductor solutions. This is a hands-on, cross-functional engineering role covering hardware partner development and qualification, international stranding partnerships, product testing, supplier quality, and field installation support.

The successful candidate will work closely with hardware manufacturers, conductor manufacturing partners, utilities, test laboratories, contractors, and internal TS Conductor teams to move solutions from engineering development through qualification and successful field deployment.

Key Responsibilities

Hardware Partner Development & Qualification

• Develop and maintain strong technical relationships with existing and new hardware manufacturing partners supporting TS Conductor products.
• Lead the development and qualification of hardware solutions including compression dead-ends, mid-span splices, tension clamps, suspension systems, dampers, connectors, and related conductor fittings.
• Establish technical and qualification requirements based on conductor characteristics, installation requirements, applicable standards, and utility expectations.
• Work collaboratively with partners on hardware design and optimization, including 3D models, engineering drawings, material selection, tolerances, Bills of Materials, manufacturing specifications, and design reviews where required.
• Coordinate prototypes and samples, internal evaluations, third-party laboratory testing, field trials, and final product qualification.
• Define and execute qualification programs including mechanical, thermal, electrical, fatigue, vibration, and cyclic performance testing as applicable.
• Review test results and failure modes, identify root causes, and drive design, manufacturing, or installation improvements through successful resolution.
• Develop and review QA/QC requirements, inspection criteria, manufacturing controls, and acceptance requirements for qualified hardware.
• Conduct supplier technical assessments, factory audits, quality audits, and Factory Acceptance Testing where required.
• Develop and maintain qualification reports, technical specifications, installation instructions, drawings, application guidelines, and catalogue information.
• Expand the portfolio of qualified hardware solutions and partners to support TS Conductor projects in North America and international markets.
• Coordinate with Sales, Application Engineering, Operations, and hardware partners to provide customers with complete and properly qualified conductor and hardware solution packages.

Stranding Partnerships

• Develop, qualify, and provide ongoing technical support to international conductor manufacturers that strand finished conductor using TS Conductor encapsulated core.
• Establish technical requirements for core handling, stranding, process controls, conductor construction, inspection, QC testing, packaging, storage, and finished-product acceptance.
• Review manufacturing processes and equipment to ensure compatibility with TS Conductor products and specifications.
• Coordinate trial production, sample evaluation, TS laboratory testing, and third-party qualification testing.
• Conduct technical assessments, factory audits, and quality reviews during initial qualification and ongoing production.
• Troubleshoot manufacturing and product-performance issues and work with partners to implement corrective and preventive actions.
• Develop technical procedures, quality documentation, training materials, and manufacturing guidelines for partner facilities.
• Support expansion of the qualified stranding partner network as TS Conductor enters new international markets.

Testing, Qualification & Technical Problem Solving

• Plan and manage conductor and hardware qualification programs with internal and external laboratories.
• Develop test plans, procedures, instrumentation requirements, acceptance criteria, and technical reports.
• Coordinate samples, fixtures, hardware, laboratory schedules, test execution, and technical reviews.
• Analyze mechanical, electrical, thermal, fatigue, vibration, and cyclic test results and translate findings into actionable product improvements.
• Lead technical investigations and root-cause analysis of qualification, manufacturing, and field issues.
• Work with partners and internal teams to implement and validate corrective actions.
• Apply relevant IEEE, ASTM, ANSI/NEMA, IEC, and utility standards to product development and qualification activities.

Field Installation & Training

• Provide onsite engineering support for conductor and hardware installations.
• Support pre-installation planning, installation readiness reviews, and contractor coordination.
• Develop and maintain conductor and hardware installation procedures, work instructions, and field guidelines.
• Provide technical training to utilities, contractors, manufacturing partners, and installation crews.
• Troubleshoot installation and hardware issues in the field and coordinate timely technical resolution.
• Capture field experience and lessons learned and incorporate them into product designs, qualification requirements, manufacturing controls, and installation practices.

Cross-Functional Product Support

• Serve as a technical interface between Technology, Application Engineering, Sales, Operations, Quality, manufacturing partners, hardware partners, laboratories, and customers.
• Support technical customer discussions involving conductor hardware, qualification, installation, and manufacturing readiness.
• Review project-specific hardware and installation requirements and identify technical risks before field deployment.
• Help standardize qualified hardware configurations, testing requirements, installation practices, and technical documentation across the TS Conductor product portfolio.
• Support continuous improvement of conductor, hardware, manufacturing, and installation solutions based on laboratory, manufacturing, and field experience.

Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Engineering, or a related engineering discipline.

• 5+ years of relevant engineering experience, preferably involving overhead transmission conductors, conductor hardware, insulators, or transmission-line components.

• Strong understanding of overhead transmission components such as conductor, insulators, hardware, and fittings.

• Experience developing, evaluating, qualifying, manufacturing, or applying engineered mechanical products.

• Experience with engineering drawings, specifications, tolerances, Bills of Materials, manufacturing processes, and quality-control requirements.

• Experience planning or executing product qualification and laboratory testing.

• Working knowledge of applicable IEEE, ASTM, ANSI/NEMA, IEC, and utility requirements.

• Strong technical problem-solving and root-cause-analysis capability.

• Ability to work effectively with external manufacturing partners, suppliers, laboratories, utilities, contractors, field crews, and internal commercial and engineering teams.

• Comfortable working hands-on in manufacturing facilities, laboratories, and field environments.

• Ability and willingness to travel 25-50% domestically and internationally.

Preferred Qualifications

• Direct experience with overhead transmission conductor hardware, conductors, insulators, or transmission-line systems.
• Experience with compression fittings, mechanical clamps, conductor accessories, or conductor installation.
• Proficiency with 3D CAD and engineering drawing software, such as SolidWorks, Creo, Inventor, or equivalent.
• Experience with mechanical testing including tensile, fatigue, thermal cycling, vibration, or cyclic-load testing.
• Experience conducting supplier qualification, factory audits, quality audits, or Factory Acceptance Testing.
• Familiarity with aluminum conductors, composite-core conductors, metallurgy, mechanical design, and transmission-line installation practices.

What Success Looks Like

The successful engineer will become a key technical owner of the hardware and conductor stranding partner ecosystem supporting TS Conductor.

This individual will build and qualify reliable hardware solutions, expand TS Conductor's international manufacturing capabilities, solve technical issues from the laboratory through the field, and help ensure that every TS Conductor project is supported by qualified products, documented installation practices, and capable manufacturing partners.