Process Development Engineer, Laser Welding

What to Expect

We're seeking elite engineers to develop advanced manufacturing processes for next‑generation battery cells – the beating heart of every Tesla product. These cells will help make clean energy more affordable and widespread, supporting our mission to speed up the shift to sustainable energy and abundance.

In this role, you'll own and develop one or more laser welding processes for cell assembly. You will collaborate with teams from design, build & test equipment, quality, vendors, and others to create fixtures, run experiments, measure, analyze, iterate, and validate. You'll turn parts into finished cell products that power real change.

Expect a fast‑paced environment with real challenges and tight deadlines, where your ideas matter and success depends on strong first principles problem‑solving and teamwork. Our team values clear communication, understanding others' views, a hands‑on approach, and continuous learning. You'll work alongside experts, new talent, and leaders from across Tesla, growing your capabilities every day while staying focused on our shared goals.

• Design and develop laser welding manufacturing processes from lab‑scale to high‑volume production, improving quality, reducing costs, and increasing efficiency.
• Hands‑on engagement with manufacturing/test equipment and automation development.
• Design and run experiments to identify key process parameters; optimize processes to improve process capability, quality, and yield, and decrease cycle time.
• Use software tools to develop predictive insights into tool and process performance to unlock manufacturing performance and improve safety while reducing cost.
• Work independently and with vendors to understand root causes of failures, propose design or component changes, equipment modifications, and ultimately implement and validate process changes.
• Define, release, and maintain technical documentation including process specifications, manufacturing instructions, and PFMEA.
• Occasional travel to Tesla factories, satellite team sites, and suppliers (domestic/international as needed).

• Degree or equivalent experience in Mechanical Engineering, Engineering Physics, Mechatronics, or a related field.
• 5+ years of experience as a laser welding process engineer (process development, process capability, troubleshooting, testing & validation, data acquisition & analysis).
• Robust fundamentals in lasers, heat transfer, phase change, weldability of materials and demonstrated application to solve thorny problems.
• Demonstrated ability to design and execute experiments, analyze data, and apply structured problem‑solving (DOE, FMEA, 5‑Why).
• Experience evaluating a process for scalability and ultimately scaling the process into mass production.
• Hands‑on experience with automated equipment, sensors, robots, PLCs, and material handling equipment.
• Proficiency with hands‑on fabrication skills.
• Proficiency in 3D CAD modeling (CATIA V5/V6 experience is a plus).
• Foundational knowledge in GD&T (proficiency is a plus).
• Excellent communication skills (interpersonal & technical); willingness to lead discussions with internal & external groups; a team‑first attitude.

Along 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 deduction.
• Family‑building, fertility, adoption and surrogacy benefits.
• Dental (including orthodontic coverage) and vision plans, both with options at $0 paycheck contribution.
• Company‑paid Health Savings Account (HSA) contribution when enrolled in the 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 to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance.
• Weight Loss and Tobacco Cessation Programs.
• Tesla Babies program.
• Commuter benefits.
• Employee discounts and perks program.

$91,600 – $164,400 / 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 depending on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.