Resistance Welding Engineer

2 weeks ago

Reston, Virginia, United States Nesco Resource Full time

Job Title: Senior Resistance Welding Engineer

Job Summary:

This role requires a highly skilled engineer with extensive experience in designing and developing resistance welding machines, including spot welders, seam welders, and projection welders. The engineer will collaborate with cross-functional teams, taking projects from concept through manufacturing, assembly, and commissioning. A strong understanding of welding processes, materials, equipment, and the ability to perform engineering analysis is crucial. Excellent problem-solving, communication, and analytical skills are essential.

Key Responsibilities:

  • Design and develop resistance welding machines, focusing on performance and manufacturability.
  • Conduct feasibility studies, cost analyses, and create detailed engineering drawings for welding systems.
  • Perform engineering analysis, redesigns, and troubleshooting of complex components, ensuring optimal selection of parts, components, and materials.
  • Collaborate with teams to integrate welding machines into production lines or automation systems.
  • Troubleshoot welding machine issues and provide technical guidance for cross-functional teams.
  • Support part selection, electrode material analysis, water cooling loads, transformer sizing, and weld heat dissipation calculations.
  • Provide engineering support for purchasing, quality, assembly, and sales teams, as well as assisting with technical guidance on non-conformances and new concepts.
  • Mentor junior engineers and stay current with industry advancements in resistance welding technology.

Requirements:

  • Bachelor's degree in Mechanical Engineering with 8+ years of relevant experience or a Master's degree with 5+ years of experience.
  • Proven experience in the design of resistance welding machines, including various types of welders.
  • Expertise in component design, manufacturing processes, material science, and GD&T.
  • Proficient in electrode material selection, cooling system design, and transformer sizing.
  • Experience with fabrication and Design for Manufacturing and Assembly (DFMA).
  • Skilled in machining processes and standards.
  • Strong expertise in SolidWorks, including FEA analysis.
  • Excellent written, verbal, and interpersonal communication skills, with the ability to collaborate with global and cross-functional teams.
  • Ability to work independently and adapt to changing project priorities while maintaining attention to budget and project timelines.

Preferred Qualifications:

  • Knowledge of additional welding processes, such as MIG, TIG, and laser welding, is a plus.
  • Familiarity with ANSI B11.19 safety regulations and experience with welding automation and robotics.
  • Registered Professional Engineer or in the process of obtaining a license, preferably in machine design and materials.
  • Basic knowledge of Lean and Six Sigma concepts is advantageous.

Work Environment:

  • Regularly works at a computer station with occasional hands-on tasks involving basic hand tools.
  • May need to stand, walk, kneel, and squat as required by the job.
  • Occasional exposure to fumes, noise, and temperature fluctuations in a manufacturing environment.

Equipment Used:

  • SolidWorks, AutoCAD
  • Laboratory test equipment
  • Microsoft Office Suite
  • Various measurement tools (calipers, micrometers)

Nesco Resource offers a comprehensive benefits package for our associates, which includes a MEC (Minimum Essential Coverage) plan that encompasses Medical, Vision, Dental, 401K, and EAP (Employee Assistance Program) services.

Nesco Resource provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws.

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