Laser Development Manufacturing Engineer

Tesla is seeking a highly motivated Manufacturing Engineer to join the Manufacturing Engineering team in Fremont, CA. This role is central to developing scalable, high-volume manufacturing processes for next-generation products across Powertrain and Optimus, and more. You will lead the end-to-end development of laser and advanced joining processes, drive automation integration, and enable production readiness. You will work at the intersection of process innovation, mechanical design, and high-speed automation - transforming prototype concepts into robust, factory-ready manufacturing solutions. This is a hands-on, fast-paced role for someone who thrives in a dynamic environment and is passionate about building the future of abundance at scale.

• Lead the development and optimization of laser-based processes (welding, surface texturing, coating removal) and alternative joining technologies (ultrasonic, resistance, friction stir, arc welding) for robotic components using metals (Al, Cu, steel) and high-performance polymers (PEEK, nylon, PET)
• Design and execute design of experiments (DOEs) to define process windows, characterize material behavior under dynamic conditions, and ensure repeatability and reliability at scale
• Perform comprehensive process validation using advanced characterization tools: high-speed imaging, cross-sectioning, SEM/EDS, CT scanning, tensile/fatigue testing, thermal imaging, and surface roughness analysis
• Develop and integrate real-time online quality control systems using sensor technologies such as Laser Weld Monitoring (LWM), Optical Coherence Tomography (OCT), and in-line thermal imaging to enable closed-loop process control
• Collaborate closely with Mechanical Design Engineering, Test & Validation, and Automation Integration teams to prototype, test, and iterate on robotic subassemblies and assembly workflows
• Translate validated processes into production-ready specifications, working with manufacturing teams and machine integrators to define automation architecture, equipment setup, and process flow for high-volume lines
• Champion Design for Manufacturability principles, proactively identifying and resolving design constraints early in the development cycle to maximize yield, reduce cost, and improve scalability
• Document processes, standards, and troubleshooting protocols to support training, audit readiness, and continuous improvement

• Hands-on experience in manufacturing process development, including laser welding, surface texturing, and advanced joining methods (ultrasonic, friction stir, resistance) for metals and high-performance polymers, with demonstrated success transitioning processes from lab-scale to high-volume production
• Proven ability to design and execute DOEs, validate processes using advanced characterization (CT, SEM/EDS, tensile, high-speed imaging), and integrate real-time quality monitoring (LWM, OCT, thermal imaging)
• Proficient in operating and programming industrial laser systems (TRUMPF, Coherent, IPG) and collaborating with automation teams on robotic cell integration and workflow design
• Strong track record in Design for Manufacturability, cross-functional collaboration, and driving process improvements in fast-paced, high-velocity environments
• Degree in Mechanical Engineering with 1+ years of relevant experience, or equivalent experience

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans > plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D
• Short-term and long-term disability insurance (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.