Sr. Manufacturing Engineer (Connector, Harness & Cable)

As a Senior Manufacturing Interconnection Engineer (Connector, Harness & Cable), you will own the end-to-end interconnection assembly design integration of TeraWave modules — bridging connector selection, harness and cable design, and volume production readiness. As a foundational element of TeraWave operations, hardware must be architected not only for performance but for manufacturability, testability, reliability, and serviceability at constellation scale. This is a hands-on role for an engineer who has designed, integrated, and shipped complex connector, harness, and cable assemblies in fast-moving, high-volume manufacturing environments and wants to apply that experience to hardware operating at orbital scale.

Special Mentions:

• Relocation assistance is available for qualified candidates.
• Travel: Up to 50%.

Responsibilities:

Interconnection Assembly Design, Integration & Manufacturing

• Lead interconnection assembly design for satellite modules and subsystems: connector selection, harness routing, cable design, wire termination, backshell integration, and mechanical integration of interconnection hardware.
• Own interconnection assembly process development — including crimping, soldering, potting, strain relief, connectorization, continuity testing, and integration workflows — to ensure robust, repeatable assembly.
• Manage connector/harness/cable BOM procurement, vendor coordination, wire and connector tolerance analysis, and assembly oversight.
• Drive first-article inspection, continuity and performance validation, process validation, and manufacturing readiness reviews to support production ramp.

Design for Excellence (DFX)

• Drive Design for Excellence (DFX) principles — DFM, DFT, DFA, DFR, and DFS — across the full interconnection assembly lifecycle to ensure hardware scales from prototype through volume production for TeraWave operations.
• Design for Manufacturability (DFM): Optimize connector selection, harness routing, wire gauge and termination methods, and assembly processes to maximize yield and minimize cost at constellation-scale production volumes.
• Design for Test (DFT): Architect continuity test points, connector mating references, and automated test coverage to enable efficient factory acceptance and in-field diagnostics.
• Design for Assembly (DFA): Simplify connector count, keying/polarization, routing, and termination methods to reduce assembly time, rework, and error rates on the line.
• Design for Reliability (DFR): Apply derating, worst-case analysis, FMEA, thermal-mechanical and vibration analysis, and reliability prediction to ensure stable interconnection performance and long-duration operation in the orbital environment.
• Design for Serviceability/Supply Chain (DFS): Coordinate with supply chain and manufacturing partners to drive connector and wire standardization, second-sourcing strategies, and obsolescence mitigation across the production lifecycle.
• Partner with manufacturing, quality, and supply chain teams to define acceptance criteria, drive yield optimization, and support production ramp for sustained TeraWave operations.

Minimum Qualifications:

• Bachelor's degree in Electrical Engineering, Mechanical Engineering, or a related field.
• 10+ years of experience in interconnection design, harness/cable engineering, or electromechanical assembly in a product development and volume production environment.
• Experience designing connector, harness, and cable assemblies with tight performance and reliability requirements; proficiency in harness design tools (Capital, Zuken E3, SolidWorks Electrical, or equivalent).
• Hands-on experience with interconnection assembly processes, including crimping, soldering, potting, connectorization, continuity test, and line bring-up.
• Demonstrated application of DFX principles (DFM/DFT/DFA/DFR) in bringing interconnection assemblies from design into volume production.
• Excellent technical documentation and communication skills.

Preferred Qualifications:

• Master's degree in Electrical or Mechanical Engineering.
• 15+ years of relevant experience.
• Experience with high-reliability connectors, high-speed/RF cabling, and space-grade wire and harness standards (IPC/WHMA-A-620, NASA-STD-8739).
• Experience with harness routing analysis, EMI/EMC shielding, and signal integrity in a design context.
• Experience designing and manufacturing interconnection hardware for space, aviation, or other high-reliability thermal-vacuum environments.
• Experience with automated harness manufacturing, wire processing equipment, and test systems.
• Background in production hardware including comprehensive DFX practices (DFM/DFT/DFA/DFR), process optimization, supply chain coordination, and yield optimization at scale.
• Hands-on environmental qualification testing (TVAC, vibration, EMI/EMC).