Lead Senior Product Development Engineer (hybrid)

Lead Senior Product Development Engineer

AFL manufactures industry-leading fiber optic cable, connectivity and accessories and provides engineering and installation services for some of the largest telecom customers in the world. Our company was founded in 1984 with a single fiber optic cable and today, we manufacture thousands of products, generate an excess of $2B in revenue, and employ approximately 9,000 associates worldwide. At AFL, we recognize that our employees are our greatest asset. We hire and train each individual, investing in them to ensure success in their careers. With a commitment to professional development and growth, let us connect you to your next career opportunity.

We are seeking a Lead Senior Product Development Engineer to join our team in Dallas, TX.

The lead senior product development engineer will be responsible for leading all activities pertaining to the design and development of fiber optic connectivity products using advanced 3D modeling and engineering analysis tools, while ensuring manufacturability and performance through detailed testing and documentation. It requires close collaboration with cross-functional teams to define specifications, verify fitment, and apply engineering principles like DFx and FMEA to optimize product quality and reliability. Additionally, the position supports prototype development, testing, and provides technical expertise to internal and external stakeholders throughout the product lifecycle.

Responsibilities

• Design and develop new ISP (Inside Plant) fiber optic terminated connectivity, cable management, and splicing apparatus products utilizing advanced 3D modeling and analysis software (SolidWorks, Finite Element Analysis, Mold Flow, etc.)
• Collaborate with other project stakeholders to develop product specifications and requirements for complex development projects.
• Conduct product design, detailing and fitment verifications. Develop manufacturing drawings and associated design documentation.
• Conduct tolerance analysis and analyze CAD models to ensure proper fitment of parts within assemblies.
• Coordinate and build engineering prototypes for design verification of fitment and performance testing.
• Lead testing, process, materials, capital, and quality improvement projects.
• Define product testing requirements and plans based on industry standards and other relevant inputs.
• Direct post design verification testing analysis, as needed, to identify potential design improvement opportunities.
• Apply DFx principles (Design for Manufacturing, Design for Assembly, etc.).
• Complete DFMEA/PFMEA (Design/Process Failure Modes Effects Analysis) and Mold Flow analysis.
• Apply engineering analysis to make data-driven design decisions.
• Use sound engineering principles and practices to develop practical solutions to complex problems and to develop new technologies that serve to evolve AFL's product portfolio.
• Interface with cross-functional project teams consisting of product management, application engineering, process and manufacturing engineering, quality, and development engineering during all phases of product development, including ramp-up and release to manufacturing.
• Gain and apply comprehensive understanding of fiber optic product installation, test and application methods to all new product development projects.
• Provide internal and external customers with product design, applications, and fiber expertise as needed.
• Adhere to and promote the environmental, health & safety policies of AFL.
• Perform other product development related duties as required.

Qualifications

• Bachelor of Science in Mechanical Engineering (or other similar technical discipline)
• Parametric solid modeling experience (SolidWorks preferred).
• 8+ years of technical experience conducting new product development.
• Design experience with multiple manufacturing techniques (injection molding, sheet metal forming, machining, bonding, etc.)
• Substantial experience designing molded plastic parts.
• Experience working within an ISO-9001 quality management system.
• Effective oral and written communication skills.
• Strong interpersonal, influencing and teamwork skills.
• Effective time management and organizational skills.
• Ability to lead new product development projects from concept through design, development, testing and Industrialization while following a formal stage-gate process using industry recognized project management practices.

Personal Qualities

• Initiative – willingness to take on additional responsibilities.
• Teamwork – works effectively in a cross-functional team environment.
• Communication – possess strong written and verbal skills.
• Flexible - detail oriented and able to quickly adapt under pressure to meet deadlines.
• Experience – has a high level of new product development engineering experience and can manage complex projects.

Preferred Skills (Not Required)

• Fiber Optic industry experience, especially design, development, and/or applications.
• Demonstrated ability to create innovative solutions and designs (Patents, Intellectual Property).
• Experience analyzing patents and drafting invention disclosures.
• Project management experience.
• Fiber optic connector and module design experience.
• Terminated fiber optic cable assembly and component design experience.
• Fiber management enclosure development and testing experience.

Working Conditions

• Office environment interacting with manufacturing and testing personnel.
• Hybrid office work schedule with additional office time required as needed by project and/or business demands.
• Domestic and international travel up to 25% may be required.