Sr. Laser Welding Engineer

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What To Expect

Tesla is seeking a highly motivated engineer to develop and scale up laser welding processes for Tesla’s high volume manufacturing lines. Specifically, this engineer is expected to be a Subject Matter Expert (SME) in the field of laser welding including metal welding (conductive, keyhole), transmission welding (plastics), laser ablation and in-line metrology. The engineer will work closely with Tesla’s internal Equipment Design, Product Design, Production and Quality Engineering teams, and coordinate cross-functional design activities with equipment vendors. This individual will assume ownership of the design and technical transfer of the laser welding tools to Tesla Operations, qualifying them for use with the highest standards of safety, quality, and output. This individual would be based in Markham, Ontario but would function as a global expert of these systems and some international travel will be required.

What You\'ll Do

• Lead development of innovative laser welding processes from proof-of-concept to full-scale production, including metals (conductive/keyhole modes), plastics (transmission welding), and hybrid joining techniques
• Conduct Design of Experiments (DOE) to optimize parameters (e.g., power, speed, focus) and perform sensitivity studies for robust, high-yield processes
• Select and integrate laser welding hardware (fiber, CO2, disk lasers) with external vendors, ensuring alignment with Tesla’s performance and scalability goals
• Develop in-line and offline metrology systems for real-time quality monitoring and post-process validation
• Serve as the subject matter expert (SME) for laser welding, guiding technical decisions including laser safety design and Design for Manufacturability (DFM)
• Support equipment qualification and ramp-up to high-volume production, troubleshooting defects, downtime, or scale-up challenges
• Develop alternate attachment methods (e.g., ultrasonic welding, resistance welding, adhesive bonding, swaging, crimping, press-fit) when laser welding is suboptimal
• Drive continuous improvement through data analysis, root cause investigations, and cross-functional collaboration
• Communicate technical findings effectively to peers, leadership, and external partners

What You\'ll Bring

• Degree or Equivalent Experience in Mechanical Engineering, Materials Science, or a related field
• 5+ years of hands-on experience in laser welding applications (fiber, CO2, disk lasers) for metals (steel, aluminum, copper) and plastics, ideally in automotive, aerospace, or battery manufacturing
• Demonstrated expertise as a subject matter expert (SME) in laser welding, with a track record of transitioning processes from R&D to high-volume production
• Proficiency in DOE methodologies, sensitivity analysis, and metrology tools (e.g., high-speed imaging, non-destructive testing, 3D profilometry)
• Experience collaborating with external vendors for hardware selection, integration, and customization of laser systems
• Strong analytical skills with software/tools (e.g., JMP, Minitab, MATLAB, Python) for process optimization and data-driven decision-making
• Ability to travel domestically and internationally to support global manufacturing initiatives

Seniority level

• Mid-Senior level

Employment type

• Full-time

Job function

• Engineering and Information Technology

Industries

• Motor Vehicle Manufacturing, Renewable Energy Semiconductor Manufacturing, and Utilities

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