Sr. Manufacturing Engineer, Laser Welding, Tabless

Tesla is seeking a Manufacturing Engineer to serve as the technical authority for laser welding, laser ablation, and inline laser inspection across our next-generation Tabless battery cell manufacturing lines at Gigafactory Texas. Unlike a standard process role, this position owns the end-to-end technical roadmap, physics-level process characterization, and high-volume industrialization of state-of-the-art laser systems from lab feasibility through mass production.

You will lead the architecture, development, and production ramp of custom, ultra-high-speed automated manufacturing systems that wind, weld, ablate, and inspect tabless cell assemblies. Working at the intersection of Cell Product Design, Equipment Engineering, Controls, Quality, and Operations, you will influence cell design for weldability, drive next-generation equipment specifications with global laser and automation suppliers, and solve the hardest metallurgical and optical challenges on the factory floor.

As a global subject matter expert based in Austin, Texas, you will set process and equipment standards across lines, lead technical transfers into Tesla Operations, and mentor a growing team of engineers and technicians. Some domestic and international travel to supplier and partner sites will be required.

• Architect, develop, and qualify advanced laser processes - including high-speed thin-foil and tabless collector welding, can-to-cap sealing, laser ablation/cleaning, and inline inspection - using rigorous laboratory and metallurgical analysis
• Serve as the primary technical authority (SME) on laser-material interaction, beam delivery and shaping optics, galvo scanning systems, and real-time weld monitoring (e.g., OCT, photodiode/spectrometry, high-speed vision)
• Own the multi-generation laser equipment roadmap and machine specifications, leading vendor evaluation, optical/mechanical design reviews, FAT/SAT qualifications, and technical transfer to Operations
• Partner early with Cell Product Design to drive Design for Manufacturability (DFM) on foil, collector, and housing geometries to widen process windows and maximize weld robustness
• Lead DFMEA/PFMEA risk assessments, Design of Experiments (DoE), and Statistical Process Control (SPC) to establish capable process windows and maximize Cpk, yield, machine availability, and OEE
• Drive installation, commissioning, qualification, and ramp-up of high-speed laser manufacturing lines while optimizing product flow, reducing capex and lead time, and compressing cycle time
• Lead safety and ergonomic engineering for high-power laser systems, ensuring Class 1 enclosures, interlocks, fume/particulate extraction, and optics handling meet or exceed ANSI Z136.1 and EH&S standards
• Act as the escalation lead for complex downtime and yield excursions, using physics-based root-cause analysis to eliminate chronic failure modes
• Establish plant-wide standards for laser power/caustic calibration, preventive maintenance, critical spares, and manufacturing instructions
• Mentor and coach engineers and maintenance technicians on laser physics, optical diagnostics, and structured problem-solving to elevate internal team capability

• Degree or equivalent experience in Physics, Optical Engineering, Materials Science, Mechanical Engineering, Welding/Metallurgical Engineering, or a related discipline, with 7+ years (Senior) or 10+ years (Staff) of relevant experience
• 5+ years of deep, hands-on experience developing, qualifying, and scaling industrial laser material processing systems (CW/pulsed fiber, disk, green/IR, or ultrafast lasers for welding and ablation)
• Strong fundamental grasp of laser-material interaction, thin-foil and dissimilar-metal metallurgy (copper, aluminum, steel), beam delivery/shaping optics, and high-speed galvo scanners
• Experience integrating and validating inline weld monitoring and characterization tools such as Optical Coherence Tomography (OCT), photodiode sensors, metallographic cross-sectioning, and CT/X-ray inspection
• Proven track record taking custom, high-volume automated manufacturing equipment from concept and supplier specification through FAT/SAT, commissioning, and production ramp
• Proficiency with 3D CAD software (SolidWorks preferred) to design and review weld fixtures, clamping tooling, shielding gas delivery, and optical path layouts
• Mastery of data-driven problem-solving and statistical analysis (DoE, SPC, Gage R&R, JMP, Minitab, or Python) applied to complex multi-variable manufacturing processes
• Working knowledge of industrial laser safety standards (ANSI Z136.1), fume extraction design, and automated PLC/motion/vision integration
• Demonstrated technical leadership, cross-functional influence, and ability to mentor engineers and drive global suppliers in a fast-paced manufacturing environment

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans > plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D
• Short-term and long-term disability insurance (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)