Ford Motor Company · 1 day ago
Laser Welding Engineer - Battery Manufacturing Engineering
Dearborn, MI
Full-time
Hybrid
Entry, Mid Level
2+ years expFord Motor Company is rapidly scaling next-generation battery manufacturing for future electric vehicles. They are seeking a Laser Welding Engineer to develop, industrialize, and optimize laser joining processes for battery cell cans and busbar assemblies, ensuring robust and scalable solutions for global EV programs.
AutomotiveAutonomous VehiclesManufacturingTransportation
No H1B
Responsibilities
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
Specify and validate laser systems and subsystems: Fiber lasers (CW and pulsed), beam delivery optics, scanners, galvos, clamping/fixturing, and motion/robot systems
Vision systems for seam tracking, part localization, and weld path alignment
Inline weld monitoring (e.g., photodiode, pyrometer, imaging, acoustic/optical sensors)
Define and implement tooling and fixturing concepts that ensure repeatable cell positioning, pressure/contact, alignment, and thermal management
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
Define critical-to-quality (CTQ) characteristics, inspection methods, and acceptance criteria; establish inline and offline inspection strategies
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
Qualification
Required
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
Demonstrated experience with: 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)
Preferred
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
Direct experience with: 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
Proficiency with engineering tools and systems such as: CAD tools (e.g., CATIA, NX, 3DX) for joint and fixture reviews
Data analysis tools (e.g., Minitab, JMP, Python, MATLAB, Excel)
Quality tools (PFMEA, control plans, SPC, 8D, 5-Why)
Experience working with equipment OEMs and system integrators: defining URS/FRS, reviewing designs, and overseeing build/commissioning
Knowledge of relevant standards and guidelines (ISO/ANSI laser safety, automotive quality systems, battery safety standards)
Benefits
Immediate medical, dental, vision and prescription drug coverage
Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
Vehicle discount program for employees and family members and management leases
Tuition assistance
Established and active employee resource groups
Paid time off for individual and team community service
A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
Paid time off and the option to purchase additional vacation time.
Company
Ford Motor Company
We don't just make history -- we make the future.
10001+ employees
Funding
Current Stage
Public CompanyTotal Funding
$16.23BKey Investors
US Department of EnergySoros Fund Management
2025-07-29Post Ipo Debt· $3B
2023-08-17Post Ipo Debt· $4B
2023-06-22Debt Financing· $9.2B
Leadership Team
James Farley
Chief Executive Officer
Efrat Barit
COO
Recent News
2026-01-07
2026-01-07
MarketScreener
2026-01-06
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