EV Connector Design - Besmak Components Pvt Ltd, Chennai

Role & responsibilities

Job Description (JD) for an EV Connector Design Engineer

Role: EV Connector Asst manager

Industry: Automotive

Experience: 6-8 years

Key Responsibilities:

• Design and develop EV electrical connectors, terminals, headers, and high-voltage connectors
• Create and maintain 3D models, 2D drawings, GD&T, BOMs, and engineering specifications
• Perform connector design considering current rating, voltage rating, creepage/clearance, temperature, sealing, mechanical strength, and manufacturability.
• Develop HV connectors, busbar interfaces, charging connectors, and interconnect systems for EV applications.
• Select suitable materials for terminals, housings, seals, CPA/TPA, and secondary locking mechanisms
• Conduct DFMEA, DVP&R, tolerance stack-up, design reviews, and risk assessments.
• Work with manufacturing teams on stamping, injection molding, plating, crimping, and assembly processes
• Support validation testing such as mating/unmating force, terminal retention, vibration, temperature cycling, waterproofing/IP testing, current carrying capacity, insulation resistance, and HV dielectric tests
• Perform root-cause analysis and design improvements for field and production issues.
• Coordinate with suppliers, manufacturing, quality, testing, and vehicle/system teams.
• Ensure compliance with relevant automotive and connector standards

Required Skills:

• Strong knowledge of connector and terminal design
• Proficiency in NX.
• Knowledge of GD&T, tolerance stack-up, DFMEA, DFM/DFA
• Understanding of plastic injection molding and metal stamping
• Knowledge of terminal crimping and wire harness design
• Understanding of EV high-voltage systems and electrical interfaces
• Familiarity with automotive standards such as USCAR, LV214, ISO 16750, IEC 60529/IP ratings and applicable OEM requirements.
• Good problem-solving and cross-functional communication skills.

Preferred Experience:

• EV/HV connector development.
• Automotive connector or wiring-harness experience.
• Terminal/contact design and material selection.
• Experience with ECN/ECR, APQP, PPAP, validation and product release processes