Laser Welding Engineer

Role details

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters. 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 position....

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 production—balancing 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 Ford’s global EV programs. What you'll 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 Ford’s safety standards and industry best practices for high-power laser systems. Cross-Functional Collaboration Partner with: Battery cell and pack design teams to influence joint design, materials, and stack-ups for manufacturability and weldability (DFM/DFW). Cell and materials engineers to understand coating stacks, current collector materials, and their impact on weld behavior. Manufacturing and industrial engineering to plan line layouts, takt times, and scaling strategies.

Suppliers and integrators to 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. Launch & Continuous Improvement Support pilot builds, pre-production, and launch events at global manufacturing sites. Develop documentation and training for plant teams: process instructions, troubleshooting guides, maintenance best practices, and safety procedures. Drive continuous improvement of OEE, cycle time, yield, scrap, and consumable usage.

Benchmark industry best practices and emerging technologies in battery laser welding, monitoring, and automation; recommend adoption paths for Ford. You'll have.... Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Welding Engineering, Materials Science, Electrical Engineering, or related field. 4+ years of hands-on experience in laser welding process 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.... Master’s degree in a relevant engineering discipline, or 4+ years of relevant industrial experience. Experience with battery manufacturing (cells, modules, or packs) or high-reliability electrical interconnects. Direct experience laser welding: Dissimilar metals (e.g., Cu–Al, Al–Ni, Cu–Ni-plated steel). Thin foils, tabs, or can terminals where spatter, porosity, and HAZ control are critical. Familiarity with: 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).

You may not check every box, or your experience may look a little different from what we've 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 builder…or 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 • 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 • Generous vacation time, sick/personal time, and paid holidays, including between Christmas Eve and New Year’s Day This position is a salary grade 7 and ranges from $86,600-$144,900., This position is a salary grade 8 and ranges from $99,100-$166,200.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value. For more information on salary and benefits, click here: Visa sponsorship is 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 status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660. This position is hybrid with a requirement to be onsite four or more days per week. #LI-Hybrid #LI-VO1