Laser Welding Engineer - Battery Manufacturing Engineering

Ford Motor • Dearborn, MI

13d • Onsite

About The Position

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves? In this position... Ford is rapidly scaling next-generation battery manufacturing, including cell-to-pack architectures for our future electric vehicles. We are seeking a Laser Welding Engineer to develop, industrialize, and optimize laser joining processes between battery cell cans and busbar/current collector assemblies. In this role, you will be the technical owner of laser welding processes used to join cylindrical/prismatic battery cells to module and pack-level current collectors. You will drive process development from early concept through pilot line, launch, and high-volume production—balancing weld quality, throughput, cost, and design constraints. You will work closely with cell engineering, pack design, manufacturing, controls/automation, quality, and supplier partners to deliver robust, scalable laser welding solutions for Ford’s global EV programs.

Requirements

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Welding Engineering, Materials Science, Electrical Engineering, or related field.
• 2+ years of hands-on experience in laser welding process development, manufacturing engineering, or equipment engineering in an industrial setting.
• Demonstrated experience with: Developing and optimizing welding or joining processes (laser, resistance, TIG/MIG, ultrasonic, etc.).
• Metallurgical evaluation of welds (microstructure, defects, joint design considerations).
• Running structured experiments and analyzing data (DoE, regression, statistical analysis).

Nice To Haves

• Master’s degree in a relevant engineering discipline, or 4+ years of relevant industrial experience.
• Experience with battery manufacturing (cells, modules, or packs) or high-reliability electrical interconnects.
• Direct experience with: Laser welding dissimilar metals (e.g., Cu–Al, Al–Ni, Cu–Ni-plated steel).
• Fiber laser systems, scanner-based welding, wobble welding, and remote welding.
• Weld monitoring technologies and closed-loop process control.
• Vision-guided robotic welding or precision positioning systems.
• Proficiency with engineering tools and systems such as: CAD tools (e.g., CATIA, NX, 3DX) for joint and fixture reviews.
• Data analysis tools (e.g., Minitab, JMP, Python, MATLAB, Excel).
• Quality tools (PFMEA, control plans, SPC, 8D, 5-Why).
• Experience working with equipment OEMs and system integrators: defining URS/FRS, reviewing designs, and overseeing build/commissioning.
• Knowledge of relevant standards and guidelines (ISO/ANSI laser safety, automotive quality systems, battery safety standards).

Responsibilities

• Process Development & Industrialization
• Develop and own laser welding processes for: Joining battery cell terminals (e.g., Al, Ni-plated steel) to copper/aluminum busbars/current collectors
• Tab-less / cell-to-pack architectures and high-density interconnects
• Define and optimize welding parameters (power, speed, focus, pulse shape, shielding gas, overlap, focal position, etc.) to meet mechanical, electrical, and thermal performance requirements.
• Plan and execute structured Design of Experiments (DoE) to establish process windows, main effects, and sensitivities across cell, busbar, and fixture variants.
• Lead process characterization including pull/shear testing, microsection analysis, porosity/crack evaluation, electrical resistance, and thermal performance.
• Equipment, Tooling & Automation
• Specify and validate laser systems and subsystems: Fiber lasers (CW and pulsed), beam delivery optics, scanners, galvos, clamping/fixturing, and motion/robot systems.
• Vision systems for seam tracking, part localization, and weld path alignment.
• Inline weld monitoring (e.g., photodiode, pyrometer, imaging, acoustic/optical sensors).
• Define and implement tooling and fixturing concepts that ensure repeatable cell positioning, pressure/contact, alignment, and thermal management.
• Collaborate with controls and automation engineers to integrate laser welding equipment into automated assembly lines, including interfaces to PLCs, robots, MES, and quality systems.
• Support equipment FAT/SAT, commissioning, and ramp-up at Ford plants and pilot lines.
• Quality, Reliability & Safety
• Develop and maintain PFMEAs, control plans, and standardized work for laser welding operations.
• Define critical-to-quality (CTQ) characteristics, inspection methods, and acceptance criteria; establish inline and offline inspection strategies.
• Work with quality and product teams to correlate weld process parameters and defects to pack-level performance, durability, and abuse-test outcomes, and ensure compliance with Ford’s safety standards and industry best practices for high-power laser systems.
• Cross-Functional Collaboration
• Partner with: Battery cell and pack design teams to influence joint design, materials, and stack-ups for manufacturability and weldability (DFM/DFW).
• Cell and materials engineers to understand coating stacks, current collector materials, and their impact on weld behavior.
• Manufacturing and industrial engineering to plan line layouts, takt times, and scaling strategies.
• Suppliers and integrators to qualify equipment, tooling, and consumables.
• Provide laser welding expertise to support design reviews, technical trade studies, and cost/feasibility assessments.
• Support problem-solving activities (8D, 5-Why, Ishikawa) for build issues, field returns, and validation test failures linked to weld integrity.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 5,001-10,000 employees