Laser Welding Engineer - Battery Manufacturing Engineering at Ford Global Career Site

Dearborn, Michigan, United States -

Full Time

Start Date

Immediate

Expiry Date

10 Mar, 26

Salary

0.0

Posted On

10 Dec, 25

Experience

2 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Laser Welding, Process Development, Design of Experiments, Metallurgical Evaluation, Weld Monitoring Technologies, High-Power Lasers, Automation Equipment, Manufacturing Engineering, Electrical Resistance, Thermal Performance, Quality Systems, Robotic Welding, Statistical Analysis, Equipment Commissioning, Collaboration, Problem-Solving

Industry

Motor Vehicle Manufacturing

Description

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. 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. Develop and maintain PFMEAs, control plans, and standardized work for laser welding operations. 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. 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. Work Environment: Mix of office, lab, and manufacturing floor settings; work around high-power lasers, automation equipment, and high-voltage battery systems with appropriate PPE and safety protocols. Established and active employee resource groups 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. 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). 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. 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. Experience working with equipment OEMs and system integrators: defining URS/FRS, reviewing designs, and overseeing build/commissioning.

Responsibilities

Develop and optimize laser welding processes for battery manufacturing, including defining welding parameters and leading process characterization. Collaborate with various engineering teams to integrate welding equipment into automated assembly lines and support problem-solving activities related to weld integrity.