Laser Process Development Engineer - Cell Manufacturing

Job Description

Tesla’s In-House Cell Group is seeking a Laser Process Development Engineer to pioneer the welding, ablation, and cutting applications that define our next-generation battery cells. Based in Fremont, CA, you will be the subject matter expert bridging the gap between fundamental laser physics and high-volume automated reality.

You aren't just managing a process; you are owning it. From initial "lab bench" experimentation and optical selection to scaling processes on massive pilot lines, you will drive the innovations that make Tesla’s vertical integration possible.

Job Responsibilities

• Innovate Processes: Develop novel laser applications (welding, cutting, ablation) and specify high-performance laser sources and optical delivery systems
• Experimental Mastery: Design and execute complex Design of Experiments (DOE) to map the process window and optimize for strength, conductivity, and speed
• Data-Driven Theory: Don't just observe—explain. Develop hypotheses for laser-material interactions and validate them through structured testing and cross-sectional analysis
• Statistical Rigor: Perform Measurement System Analysis (Gage R&R) and utilize statistical process control (SPC) to ensure every micron of every weld is accounted for
• Scale Up: Lead the technical transfer of processes from the lab to the production floor. Manage the installation, commissioning, and qualification (IQ/OQ/PQ) of laser-integrated automation
• Cross-Functional Leadership: Partner with Product Design to influence "Design for Manufacturability" (DFM) and collaborate with Controls and Quality to ensure 100% yield and uptime

Job Requirements

• Degree or Equivalent Experience in Mechanical Engineering, Materials Science, Physics, or Mechatronics
•  6+ years in process development, specifically transitioning technologies from pilot-scale to high-volume manufacturing (HVM)
• Deep familiarity with industrial laser systems (Fiber, CO2, Green/Blue/UV), beam delivery optics, and metrology (profilometry, microscopy)
• A proven toolkit in structured problem-solving, including FMEA, 5-Why, and advanced data analysis
• Proficiency in SolidWorks for tooling/fixture design and experience with data analysis software (JMP, Minitab, or Python/R)
• Hands-on experience with automation, sensors, and the ability to troubleshoot PLC-controlled equipment on the fly

• Strong background in thermodynamics, heat transfer, or plasma physics
• Proficiency in Python, MATLAB, or C++ for automating data collection and analysis
• Experience integrating "Through-the-Lens" (TTL) monitoring or post-weld inspection systems