Principal AME Engineer

JOB SUMMARY

A Principal AME Engineer in battery pack laser welding is a senior-level manufacturing or process engineer who serves as a subject matter expert for all laser welding processes used in battery production. The candidate must have hands-on experience in automated laser welding process design, equipment specification, system configuration, creating fixtures, defining/optimizing laser welding process parameters, in-line process or post-weld monitoring systems, and improving processes through data analysis/continuous improvement methodologies. The role also involves acting as a technical liaison between design and manufacturing, providing expertise on manufacturability, and ensuring the reliability and safety of the welding operations.

KEY RESPONSIBILITIES AND AUTHORITIES

• Process Development & Optimization

o Develop, validate and standardize laser welding processes, fixtures, and parameters to meet quality, cost, and throughput targets.

o Optimize welding process parameters (power, speed, focus, gas, clamping force…) to achieve superior joint quality, electrical conductivity, and mechanical strength using DOE, SPC, and Six Sigma methodologies.

o Perform in-depth analysis of weld metallurgy, including heat-affected zones (HAZ), penetration, leakage, nugget, porosity, microstructural changes, and material interactions, using digital microscope, cross-section, CT scan, and tensile/shear evaluations.

o Implement advanced process monitoring and control systems (LWM, Scanmaster...).

o Conduct failure mode analysis and implement robust process windows that account for material and geometric variations.

• Technical leadership:

o Act as the subject matter expert, go-to person, for all laser welding processes related to battery pack (cell-to-cell, strap welding)

o Stay updated on new technologies and seek integration opportunities.

o Provide technical guidance to cross-functional teams including design engineering, quality, manufacturing, and equipment engineering

o Lead root cause investigations for welding-related quality issues and implement corrective actions

o Mentor and develop process engineers and technicians in laser welding best practices

• Manufacturing Engineering Development

o Work with design engineers to optimize product designs for manufacturability (DFM/DFA) and with operations to support manufacturing ramp-up and production.

o Drive the transfer of laser welding processes from R&D through pilot production to high-volume manufacturing

o Lead the specification, procurement, installation, and qualification of new laser welding equipment and ensure equipment performs as required through factory and site acceptance testing.

o Collaborate with equipment suppliers to specify, commission, and optimize laser welding systems

o Develop and validate process documentation including work instructions, control plans, and FMEA.

o Establish and oversee process capability metrics, Gage R&R and drive continuous improvement initiatives to to enhance key metrics: uptime, yield, throughput, and cost.

• NPD Project Management

o Attend NPD meetings, work with the Operations Team to develop and maintain manufacturing action plans for new tooling, equipment, and production scheduling needs

o Coordinate NPD builds and follow up actions, including but not limited to Engineering Builds, Qualification Builds, and Pilot builds

o Create collaborative project communication channels with NPD, Engineering, Manufacturing, Production Scheduling, Quality, Supervision, and floor operators

o Develop and maintain Gantt Charts, Project Schedule, Risk Assessment, and Contingency Plans

o Develop agendas to facilitate and document project meetings

o Deliver formal presentations to leadership regarding project status

o Manage suppliers of capital equipment for turn-key applications / custom equipment.

REQUIREMENTS

Bachelor's degree in Battery/ Chemical Engineering/ Electrical and Electronic Engineering (most preferable) or Mechanical Engineering or Industrial Engineering or with equivalent years of directly related experience

• 5+ years of hands-on experience in laser welding process engineering, with at least 2 years in battery or automotive manufacturing

• Proven track record of launching laser welding processes in high-volume production environments

• Proven expertise in welding of dissimilar materials critical to battery packs (e.g., Copper-to-Aluminum, Aluminum-to-Aluminum, Steel-to-Aluminum).

• Deep understanding of laser physics, optics, and the interaction between laser light and materials.

• Extensive experience with laser welding equipment (e.g., Trumpf, Coherent) and laser welding control and monitoring systems (Scan master, LWM…)

• Strong proficiency in statistical analysis, DOE, and data-driven problem-solving (Six Sigma Green/Black Belt is a plus).

• Experience with non-destructive testing (NDT) and destructive testing methods for weld validation.

• Familiarity with battery pack design, electrical requirements, and safety considerations

• CAD proficiency and ability to design fixture

• Deep expertise in laser physics, beam characteristics, and laser-material interactions

• Comprehensive understanding of welding metallurgy, solidification, heat-affected zones, and thermal effects

• Strong knowledge of joint design principles and weld geometry optimization

• Understanding of battery pack architecture, electrical requirements

• Familiarity with laser safety standards and regulatory compliance

• Familiarity with with automation, robotics, and Industry 4.0 concepts

• Understanding of manufacturing systems, automation, and process control principles

• Process Development: DOE methodology, process optimization, parameter development, process window establishment

• Quality Tools: SPC, FMEA, control plans, capability studies (Cpk/Ppk), root cause analysis (8D, 5-Why)

• Six Sigma: Green Belt minimum, Black Belt preferred

• Testing & Validation: Weld quality assessment including cross-sectioning, peel testing, electrical resistance measurement, tensile testing, leakage detection...

• Software Proficiency: CAD software, statistical analysis tools (Minitab, JMP), data visualization

• Technical Communication: Technical report writing, presentation development, documentation and work instruction creation

• Project Management: Resource planning, timeline management, stakeholder coordination

• Problem Solving: Data-driven decision making, analytical thinking, troubleshooting complex technical issues

• Leadership: Team leadership, mentorship, influence without authority, change management