Laser Welding Engineer Battery Manufacturing Engineering

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In this position...

Ford is rapidly scaling next-generation battery manufacturing including cell-to-pack architectures for our future electric vehicles. We are seeking a Laser Welding Engineer to develop industrialize and optimize laser joining processes between battery cell cans and busbar/current collector assemblies.

In this role you will be the technical owner of laser welding processes used to join cylindrical/prismatic battery cells to module and pack-level current collectors. You will drive process development from early concept through pilot line launch and high-volume productionbalancing weld quality throughput cost and design constraints.

You will work closely with cell engineering pack design manufacturing controls/automation quality and supplier partners to deliver robust scalable laser welding solutions for Fords global EV programs.

What youll do...

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.

Equipment Tooling & Automation

• 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.

Quality Reliability & Safety

• 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 Fords safety standards and industry best practices for high-power laser systems.

Cross-Functional Collaboration

• Partner with:
  • Battery cell and pack design teamsto influence joint design materials and stack-ups for manufacturability and weldability (DFM/DFW).
  • Cell and materials engineersto understand coating stacks current collector materials and their impact on weld behavior.
  • Manufacturing and industrial engineeringto plan line layouts takt times and scaling strategies.
  • Suppliers and integratorsto 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.

Youll have...

• Bachelors degree in Mechanical Engineering Manufacturing Engineering Welding Engineering Materials Science Electrical Engineering or related field.
• 2 years of hands-on experience inlaser weldingprocess 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).

Even better you may have...

• Masters degree in a relevant engineering discipline or 4 years of relevant industrial experience.
• Experience withbattery manufacturing(cells modules or packs) or high-reliability electrical interconnects.
• Direct experience with:
  • Laser welding dissimilar metals (e.g. CuAl AlNi CuNi-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).

Additional Details

• Travel:Up to 2030% travel will be required to support pilot builds pre-production and launch events at global Ford manufacturing sites and supplier facilities.
• 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.

You may not check every box or your experience may look a little different from what weve outlined but if you think you can bring value to Ford Motor Company we encourage you to apply!

As an established global company we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe or keep you close to home Will your career be a deep dive into what you love or a series of new teams and new skills Will you be a leader a changemaker a technical expert a culture builderor all of the above No matter what you choose we offer a work life that works for you including:

• 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 Years Day

• Paid time off and the option to purchase additional vacation time.

For more information on salary and benefits click here

This position is a range of salary grades 6 - 8 .

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race religion color age sex national origin sexual orientation gender identity disability status or protected veteran the United States if you need a reasonable accommodation for the online application process due to a disability please call 1-.

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