Process Engineer

Senior Process Engineer – Joining & Welding

Work Arrangement: Onsite

Contract: August 24, 2026 – August 20, 2027

Experience: 5+ years

Industry: Medical Devices / Advanced Manufacturing

We are seeking a Senior Process Engineer to join the Advanced Manufacturing Engineering (AME) Joining & Welding team in Brooklyn Center, Minnesota. This role will focus on the development, optimization, validation, and transfer of advanced joining and welding processes supporting cardiovascular and neurological medical devices.

The ideal candidate brings strong process engineering experience in a regulated manufacturing environment, with hands-on expertise in laser welding, resistance welding, micro-welding, or similar thermal joining technologies
.

Experience with
DOE, process validation, structured problem solving, and continuous improvement is highly valued.

You will work closely with Design Engineering, Operations, Quality, Manufacturing, and external equipment suppliers to develop robust, scalable processes and support new product introductions and continuous improvement initiatives.

• Develop, optimize, and qualify joining and welding processes for new and existing medical device products.
• Lead process improvement and cost-reduction initiatives using DMAIC, root cause analysis, and other structured problem-solving methodologies
  .
• Characterize and optimize welding parameters using Design of Experiments (DOE), capability studies, statistical analysis, and data-driven methods
  .
• Own critical process documentation, including control plans, process instructions, validation protocols and reports, and engineering change orders (ECOs).
• Execute process validation and qualification activities, including process runs, data collection, analysis, and technical report preparation.
• Collaborate with Operations and Manufacturing teams to transfer processes from development into production and support successful production ramp-up.
• Partner with equipment vendors on the specification, selection, installation, and qualification of welding equipment, fixtures, and automated joining systems.
• Support nonconformance investigations and CAPA activities through root cause analysis and implementation of effective corrective actions.
• Work cross-functionally to ensure processes meet applicable quality, regulatory, safety, and manufacturing requirements.
• Support continuous improvement of manufacturing processes, including yield, throughput, process capability, and cost performance.

• Bachelor’s degree in engineering, Materials Science, Physics, or a related technical discipline.
• 5+ years of relevant engineering experience in manufacturing, process engineering, or advanced manufacturing engineering; or 3+ years with an advanced degree.
• Hands-on experience with at least one of the following:
• Laser welding
• Resistance welding
• Micro-welding or micro-joining
• Battery or capacitor manufacturing
• Similar thermal joining processes
• Experience with structured problem-solving methodologies such as DMAIC, 5 Whys, Fishbone, and Root Cause Analysis
  .
• Experience working with engineering drawings, specifications, and manufacturing processes.
• Strong cross-functional communication and collaboration skills.
• Ability to work effectively in a regulated manufacturing environment.

• Medical device, pharmaceutical, aerospace, automotive, nuclear, or other highly regulated industry experience.
• Experience with IPG laser systems or similar laser welding technologies.
• Experience selecting, installing, commissioning, and qualifying welding or automated joining equipment.
• Familiarity with automation, robotics, machine vision, and custom manufacturing equipment.
• Knowledge of Design for Manufacturability (DFM), DOE, Minitab, statistical process control, and process capability analysis
  .
• Familiarity with ISO 13485, FDA requirements/QSR, and GMP
  .
• Experience supporting New Product Introduction (NPI) and transferring processes from development to manufacturing.
• Lean, Six Sigma, or continuous improvement experience;
  Green Belt certification is a plus.

The AME Joining & Welding team develops advanced manufacturing technologies that enable the production of complex cardiovascular and neurological medical devices. This position offers the opportunity to work on challenging joining applications, collaborate with multidisciplinary engineering teams, and directly contribute to the development of reliable, high-capability manufacturing processes.

If you are an experienced Process Engineer with a strong background in welding, process development, validation, and regulated manufacturing
, we would like to hear from you.