Laser Welding Engineer

Ford•Dearborn, MI

9d•$86,600 - $166,200•Hybrid

About The Position

Ford is seeking a Laser Welding Engineer to develop, industrialize, and optimize laser joining processes for battery cell cans and busbar/current collector assemblies. The role owns laser welding processes that connect cylindrical or prismatic battery cells to module- and pack-level current collectors, driving development from concept through pilot line, launch, and high-volume production while balancing weld quality, throughput, cost, and design constraints. The engineer works with cell engineering, pack design, manufacturing, controls and automation, quality, and suppliers to deliver scalable solutions for global electric-vehicle programs. The position develops and optimizes processes for joining battery terminals to copper or aluminum busbars, including tab-less and cell-to-pack architectures. It specifies and validates laser systems, optics, scanners, fixturing, motion systems, vision, and inline monitoring; integrates equipment into automated lines; and supports equipment acceptance, commissioning, and production ramp-up. The role also establishes process characterization, quality controls, inspection strategies, documentation, training, and safety practices. It supports launch and continuous improvement at manufacturing sites and addresses weld-related issues through structured problem-solving.

Requirements

Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Welding Engineering, Materials Science, Electrical Engineering, or a related field.
At least 4 years of hands-on industrial experience in laser welding process development, manufacturing engineering, or equipment engineering.
Demonstrated experience developing and optimizing welding or joining processes, such as laser, resistance, TIG/MIG, or ultrasonic welding.
Experience with metallurgical evaluation of welds, including microstructure, defects, and joint-design considerations.
Experience running structured experiments and analyzing data, including DoE, regression, and statistical analysis.

Nice To Haves

Master’s degree in a relevant engineering discipline, or 4+ years of relevant industrial experience.
Experience in battery manufacturing (cells, modules, or packs) or high-reliability electrical interconnects.
Direct laser-welding experience with dissimilar metals such as Cu–Al, Al–Ni, or Cu–Ni-plated steel.
Direct experience welding thin foils, tabs, or can terminals where spatter, porosity, and heat-affected-zone control are critical.
Familiarity with fiber laser systems, scanner-based welding, wobble welding, and remote welding.
Familiarity with weld-monitoring technologies and closed-loop process control.
Familiarity with vision-guided robotic welding or precision positioning systems.
Proficiency with CAD tools such as CATIA, NX, or 3DX for joint and fixture reviews.
Proficiency with data analysis tools such as Minitab, JMP, Python, MATLAB, or Excel.
Proficiency with quality tools such as PFMEA, control plans, SPC, 8D, and 5-Why.
Experience working with equipment OEMs and system integrators, including defining URS/FRS, reviewing designs, and overseeing build and commissioning.
Knowledge of relevant standards and guidelines, including ISO/ANSI laser safety, automotive quality systems, and battery safety standards.

Responsibilities

Develop and own laser welding processes for battery cell terminals and busbars/current collectors, including tab-less and cell-to-pack architectures.
Define and optimize welding parameters to meet mechanical, electrical, and thermal requirements.
Plan and execute Design of Experiments to establish process windows, effects, and sensitivities across cell, busbar, and fixture variants.
Lead process characterization through mechanical testing, microsection analysis, defect evaluation, electrical resistance measurement, and thermal performance assessment.
Specify and validate laser systems and subsystems, including lasers, beam delivery optics, scanners, clamping and fixturing, and motion or robot systems.
Specify vision systems for seam tracking, part localization, and weld path alignment, as well as inline weld-monitoring systems.
Define and implement tooling and fixturing concepts that provide repeatable cell positioning, pressure/contact, alignment, and thermal management.
Collaborate with controls and automation engineers to integrate welding equipment with automated assembly lines, PLCs, robots, MES, and quality systems.
Support equipment FAT/SAT, commissioning, and ramp-up at Ford plants and pilot lines.
Develop and maintain PFMEAs, control plans, and standardized work for laser welding operations.
Define CTQ characteristics, inspection methods, acceptance criteria, and inline and offline inspection strategies.
Correlate weld process parameters and defects with pack performance, durability, and abuse-test outcomes, and support compliance with laser safety standards and industry practices.
Partner with battery cell and pack design teams on joint design, materials, stack-ups, manufacturability, and weldability.
Work with cell and materials engineers to assess coating stacks and current collector materials and their effects on welding behavior.
Coordinate with manufacturing and industrial engineering on line layouts, takt times, and scaling strategies.
Work with suppliers and integrators to qualify equipment, tooling, and consumables.
Provide laser welding expertise for design reviews, technical trade studies, and cost and feasibility assessments.
Support 8D, 5-Why, and Ishikawa problem-solving for build issues, field returns, and validation failures related to weld integrity.
Support pilot builds, pre-production, and launch events at global manufacturing sites.
Develop plant-team documentation and training, including process instructions, troubleshooting guides, maintenance practices, and safety procedures.
Drive continuous improvement in OEE, cycle time, yield, scrap, and consumable usage.
Benchmark battery laser welding, monitoring, and automation technologies and recommend adoption paths.