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Laser Process Development Engineer, Cell Manufacturing
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What to ExpectTesla's In-House Cell Group is seeking a Laser Process Development Engineer to pioneer the welding, ablation, and cutting applications that define our next-generation battery cells. Based in Fremont, CA, you will be the subject matter expert bridging the gap between fundamental laser physics and high-volume automated reality. You aren't just managing a process; you are owning it. From initial "lab bench" experimentation and optical selection to scaling processes on massive pilot lines, you will drive the innovations that make Tesla's vertical integration possible.
What You'll DoInnovate Processes: Develop novel laser applications (welding, cutting, ablation) and specify high-performance laser sources and optical delivery systemsExperimental Mastery: Design and execute complex Design of Experiments (DOE) to map the process window and optimize for strength, conductivity, and speedData-Driven Theory: Don't just observe—explain. Develop hypotheses for laser-material interactions and validate them through structured testing and cross-sectional analysisStatistical Rigor: Perform Measurement System Analysis (Gage R&R) and utilize statistical process control (SPC) to ensure every micron of every weld is accounted forScale Up: Lead the technical transfer of processes from the lab to the production floor. Manage the installation, commissioning, and qualification (IQ/OQ/PQ) of laser-integrated automationCross-Functional Leadership: Partner with Product Design to influence "Design for Manufacturability" (DFM) and collaborate with Controls and Quality to ensure 100% yield and uptimeWhat You'll BringDegree or Equivalent Experience in Mechanical Engineering, Materials Science, Physics, or Mechatronics6+ years in process development, specifically transitioning technologies from pilot-scale to high-volume manufacturing (HVM)Deep familiarity with industrial laser systems (Fiber, CO2, Green/Blue/UV), beam delivery optics, and metrology (profilometry, microscopy)A proven toolkit in structured problem-solving, including FMEA, 5-Why, and advanced data analysisProficiency in SolidWorks for tooling/fixture design and experience with data analysis software (JMP, Minitab, or Python/R)Hands-on experience with automation, sensors, and the ability to troubleshoot PLC-controlled equipment on the flyStrong background in thermodynamics, heat transfer, or plasma physicsProficiency in Python, MATLAB, or C++ for automating data collection and analysisExperience integrating "Through-the-Lens" (TTL) monitoring or post-weld inspection systemsCompensation and BenefitsBenefitsAlong 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 deductionFamily-building, fertility, adoption and surrogacy benefitsDental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contributionCompany Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSAHealthcare and Dependent Care Flexible Spending Accounts (FSA)401(k) with employer match, Employee Stock Purchase Plans, and other financial benefitsCompany paid Basic Life, AD&DShort-term and long-term disability insurance (90 day waiting period)Employee Assistance ProgramSick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid HolidaysBack-up childcare and parenting support resourcesVoluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insuranceWeight Loss and Tobacco Cessation ProgramsTesla Babies programCommuter benefitsEmployee discounts and perks programExpected Compensation$91,600 - $164,400/annual salary + cash and stock awards + benefitsPay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered.
Details of participation in these benefit plans will be provided if an employee receives an offer of employment. Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws. Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities.
Please let your recruiter know if you need an accommodation at any point during the interview process.
