Tesla

Makes electric cars, robotaxis and grid batteries

Manufacturing Process Development Engineer

Manufacturing EngineeringUpdated on Nov 10

Full-timeFremont, CA, USANo salary listed

About the Job

Requirements

A degree or equivalent experience in Mechanical Engineering, Engineering Physics, Mechatronics, or a related field.
At least 5 years of experience as a laser welding process engineer, including process development, process capability, troubleshooting, testing and validation, and data acquisition and analysis.
Robust fundamentals in lasers, heat transfer, phase change, and weldability of materials, with demonstrated application to solve difficult problems.
Ability to design and execute experiments, analyze data, and apply structured problem-solving methods including Design of Experiments (DOE), Failure Mode and Effects Analysis (FMEA), and 5-Why.
Experience evaluating processes for scalability and scaling them into mass production.
Hands-on experience with automated equipment, sensors, robots, programmable logic controllers (PLCs), and material handling equipment.
Proficiency with hands-on fabrication skills.
Proficiency in 3D computer-aided design (CAD) modeling; CATIA V5/V6 experience is a plus.
Foundational knowledge in geometric dimensioning and tolerancing (GD&T).
Communication skills for interpersonal and technical contexts, willingness to lead discussions with internal and external groups, and a team-first attitude.

Responsibilities

Design and develop laser welding manufacturing processes from lab scale through high-volume production to improve cell product quality, reduce costs, and increase efficiency.
Work hands-on with manufacturing and test equipment and develop automation.
Design and run experiments to identify key process parameters; optimize processes to improve capability, quality, and yield and decrease cycle time.
Use software tools to develop predictive insights into tool and process performance to improve manufacturing performance and safety while reducing cost.
Work independently and with vendors to identify root causes of failures, propose design or component changes and equipment modifications, and implement and validate process changes.
Define, release, and maintain technical documentation, including process specifications, manufacturing instructions, and Process Failure Mode and Effects Analysis (PFMEA).
Travel occasionally to factories, satellite team sites, and suppliers domestically and internationally as needed.

Desired Qualifications

Experience with CATIA V5/V6 for 3D CAD modeling.
Proficiency in geometric dimensioning and tolerancing (GD&T).

Category	Manufacturing
Location	Fremont, California
Requisition ID	265691
Type	Full-time

Job Description

We're seeking elite engineers to develop advanced manufacturing processes for next-generation battery cells — the beating heart of every Tesla product. These cells will help make clean energy more affordable and widespread, supporting our mission to speed up the shift to sustainable energy and abundance.    In this role, you'll own and develop one or more laser welding processes for cell assembly. You will collaborate with teams from design, build & test equipment, quality, vendors, and others — to create fixtures, run experiments, measure, analyze, iterate, and validate. You'll turn parts into finished cell products that power real change.    Expect a fast-paced environment with real challenges and tight deadlines, where your ideas matter and success depends on strong first principles problem-solving and teamwork. Our team values clear communication, understanding others' views, hands-on approach, and continuous learning. You'll work alongside experts, new talent, and leaders from across Tesla, growing your capabilities every day while staying focused on our shared goals.

Job Responsibilities

Design and develop laser welding manufacturing processes starting at lab-scale to ultimately enable high-volume production of cell products with improved quality, reduced costs, and increased efficiency

Hands-on engagement with manufacturing / test equipment and automation development

Design and run experiments to identify key process parameters; optimize processes to improve process capability, quality, and yield; decrease cycle time

Use software tools to develop predictive insights into tool and process performance to unlock manufacturing performance and improve safety while reducing cost

Work independently and with vendors to understand root cause of failures, propose design or component changes, equipment modifications, ultimately implement and validate process changes

Define, release, and maintain technical documentation including process specifications, manufacturing instructions, and PFMEA

Occasional travel to Tesla factories, satellite team sites, and suppliers (domestic / international as needed)

Job Requirements

Degree or equivalent experience in Mechanical Engineering, Engineering Physics, Mechatronics, or a related field

5+ years of experience as a laser welding process engineer (process development, process capability, troubleshooting, testing & validation, data acquisition & analysis)

Robust fundamentals in lasers, heat transfer, phase change, weldability of materials + demonstrated application to solve thorny problems

Demonstrated ability to design and execute experiments, analyze data, and apply structured problem-solving (DOE, FMEA, 5-Why)

Experience with evaluating a process for scalability and ultimately scaling the process into mass production

Hands-on experience with automated equipment, sensors, robots, PLCs, and material handling equipment

Proficiency with hands-on fabrication skills

Proficiency in 3D CAD modeling (CATIA V5/V6 experience is a plus)

Foundational knowledge in GD&T (proficiency is a plus)

Great communication skills (interpersonal & technical); willingness to lead discussions with internal & external groups; a team-first attitude

About the Company

Tesla

Makes electric cars, robotaxis and grid batteries

Tesla makes electric cars and batteries that store power for homes and utilities, and it develops self-driving software and humanoid robots. In 2023, its Model Y became the first electric vehicle to rank as the world's best-selling car. Buyers order the Model 3 sedan, Model Y SUV, or Cybertruck pickup directly from Tesla instead of through dealers, and they charge on its Supercharger fast-charging network. It also sells Megapack and Powerwall batteries, runs a robotaxi service, and charges drivers a monthly fee for self-driving software that still needs their supervision. Tesla was founded in 2003, with Elon Musk as its lead early investor and a recognized co-founder, and it is based in Austin, Texas.

Company size: 10,001+
Company stage: IPO
Headquarters: Austin, TX
Founded: 2003

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