Sr. Laser Process Development Engineer

Overview

Tesla is seeking a highly motivated Senior Laser Process Engineer to develop, engineer and innovate new laser processes and high-volume automation equipment with the cell manufacturing team in Fremont, CA. You will be a process expert in laser welding and cutting applications, working in both lab environments and transferring processes to high-volume manufacturing. You will take ownership of new process development and process optimization for pilot-scale and mass production equipment, leading experiments, data analysis, and process characterization.

You will support the technical transfer of processes and tools to production, ensuring they meet safety, quality, and throughput standards. You will work with Product Design, Controls, Operations, Quality, and Production Engineering, and coordinate with equipment suppliers to develop scalable innovations in laser processes and tools. This role is based in Fremont, CA but will function as a global expert of these systems, so some international travel will be required.

• Develop novel laser processes and select laser process equipment
• Design and execute experiments to evaluate and optimize laser processes
• Analyze process data to identify key parameters, trends, and equipment performance
• Develop hypotheses and theories to explain observed process phenomena and validate them through structured experimentation
• Perform measurement system analysis (e.g., Gage R&R, bias, linearity) to ensure inspection reliability
• Support design, commissioning, and validation of pilot and production equipment
• Manage installation, qualification and ramp-up of manufacturing equipment including (but not limited to) systems with laser processes
• Collaborate with Production Engineering, EH&S, Quality, Operations and Product Design teams to drive toward maximum yield, quality, machine availability and output
• Generate machine specifications, documentation, and manufacturing instructions

• Degree or Equivalent Experience in Mechanical Engineering, Mechatronics, or related field
• 6+ years of experience developing processes for pilot and high-volume manufacturing
• Experience working with laser processes, equipment, and relevant metrology systems
• Demonstrated ability to design and execute experiments, analyze data, and apply structured problem-solving (DOE, FMEA, 5-Why)
• Proficiency with Solid Works or other 3D CAD software
• Proven track record of data-driven workflow to solve complex problems
• Hands-on experience with automation, sensors, and PLC-controlled equipment
• Strong mechanical aptitude, analytical mindset, and ability to translate observations into scalable process improvements

• Medical plans with multiple options and $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans with $0 paycheck contribution
• Company paid HSA contributions when enrolled in a 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 including critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program

Expected Compensation

$92,000 - $162,000/annual salary + cash and stock awards + benefits. Pay 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