Welding and Joining Engineer

Toyota Material Handling•Town of Henrietta, NY

2d•Onsite

About The Position

Toyota Material Handling North America is seeking an experienced Welding Engineer / Joining Engineer to play a key role in advancing electrified powertrains and next-generation energy storage systems for material handling equipment. In this hands-on role, you’ll develop and industrialize cutting-edge joining processes, including laser welding, resistance welding, and brazing as well as NDE (non-destructive evaluation) techniques, that enable high-performance lithium-ion battery packs and fuel cell systems. You’ll work closely with mechanical, electrical, manufacturing, and quality teams to ensure TMHNA delivers safe, reliable, and production-ready solutions for next-generation energy systems. This role sits at the intersection of welding engineering, materials science, manufacturing engineering, and failure analysis, offering a unique opportunity to shape the next generation of advanced energy systems.

Requirements

B.S. in Welding Engineering, Mechanical Engineering, Materials Science, or related discipline.
10+ years of welding engineering, welding research, or NDE experience.
Experience welding Copper, Aluminum, or high-strength steels.
Experience with NDE techniques, including X-ray or ultrasonic inspection.
Demonstrated capability in data analysis, documentation, and experimental interpretation.
Strong communication, teamwork, and interpersonal skills.
Self-starter capable of managing complex, multi-disciplinary assignments.
Passion for innovation and continuous improvement.

Nice To Haves

Master’s degree in Materials Science, Welding Engineering, Mechanical Engineering, or related field.
5+ years of advanced experience with NDE methods and complex joining technologies.
Experience with advanced development work including literature reviews, gap analysis, experimental planning, and technical reporting.
Background in automotive manufacturing, electrified powertrains, or battery systems.
Hands-on expertise in mechanical testing, metallography, and sample preparation.
Proficiency with statistical and data analysis tools (Minitab, JMP, Python, R).
Laboratory and/or plant experience supporting manufacturing process development or troubleshooting.
Familiarity with UL, IEC, EN, ANSI, AS9100, J-STD-001, and GD&T (ASME Y14.5).
Deep understanding of welding metallurgy, material transformations, and joint behavior.
Proven ability to scale advanced joining technologies into production environments.
Strong analytical mindset grounded in materials science and failure analysis.

Responsibilities

Develop and optimize joining processes, including laser welding, brazing, and bonding, for energy storage applications.
Lead metallurgy-driven process development for Aluminum, Copper and high-strength steels.
Perform metallurgical evaluations, including microstructure analysis, Heat-Affected Zone characterization, hardness testing, and weld sectioning.
Conduct weld trials, define process windows, evaluate joint quality, and ensure long-term reliability based on material behavior.
Partner with equipment suppliers to specify welding systems, tooling, jigs, fixtures, and automation.
Support the development of joining processes used in battery pack enclosures, busbars, cooling plates, and electro-mechanical interfaces.
Drive the lock-step introduction of NDE techniques alongside new joining processes, ensuring inspection strategies are fully embedded before manufacturing scale-up.
Develop NDE solutions such as X-ray/radiography, vision inspection, and weld-quality monitoring tools.
Validate NDE methods for repeatability, capability, and suitability for both prototype and high-volume manufacturing.
Implement NDE techniques that prevent scrap and reduce dependence on destructive testing.
Industrialize joining and inspection processes into manufacturing using structured process validation, tool qualification, PFMEA/DFMEA, SPC, and DOE.
Support prototype builds and transition joining processes to pilot lines and production environments.
Troubleshoot process issues involving weld quality, materials behavior, design interactions, or equipment variation.
Conduct capability studies, GR&R, weld parameter optimization, and statistical analysis to ensure process robustness.
Lead structured failure analysis for weld-related or materials-related issues, including fractography, fatigue, cracking, and corrosion mechanisms.
Document findings in clear technical reports and communicate results to engineering, quality, and manufacturing partners.
Collaborate with Mechanical Engineering, Electrical Engineering, BMS, Manufacturing, Validation, and suppliers to ensure fully integrated joining solutions.
Maintain awareness of new welding, joining, and NDE technologies, introducing innovations that strengthen TMHNA’s competitiveness.
Support both laboratory and production environments to execute trials, inspections, and troubleshooting.

Benefits

Competitive Salary
Performance Bonus
Generous Paid Time Off and 13 Paid Holidays
Affordable Medical plans and no-cost Dental & Vision options
100% 401(k) match up to 6%
Company-Paid Life Insurance, Short-Term Disability, and Long-Term Disability
Tuition Assistance Program
Employee Assistance Program (EAP) with access to mental health care, legal support, and financial guidance
Recognition and Kaizen (continuous improvement) Reward Programs
Meaningful opportunities for personal and professional development
Best in class work culture!