Manufacturing Engineer, Front-End Cell Assembly

Manufacturing Engineer, Front-End Cell Assembly | Tesla

Location: AUSTIN, Texas | Req ID: 285908 | Job Type: Full-time

What to Expect

Gigafactory Texas is seeking a strategic, highly motivated Manufacturing Development Engineer to help define and scale Tesla’s next-generation 4680 cell assembly. You will lead the design, development, and optimization of advanced manufacturing equipment and systems, driving long-term architecture for scalability, flexibility, reliability, quality, speed, and cost. You’ll collaborate closely with Design, Process, Production, Controls, R&D, and global OEM/automation partners, provide technical mentorship, and champion innovative, high-impact approaches that push battery cell manufacturing forward.

What You'll Do

• You will own end-to-end Design For Manufacturing (DFM), leading change control, process qualification, commissioning, and formal handovers for new lines, first-of-kind and duplicate equipment, retrofits, and optimization projects. Including Prototyping/FAT/SAT/GR&R/Cpk sign-off, and delivering required packages (FMEA, BOM, LOTO, SOPs, build-as-print), remain engaged post-handover for change management, OEE ramps, fleet landing plans, vendor qualification, and escalation through Change Control Boards
• Deploy, validate, and continuously optimize automated cell assembly equipment for press-fit/swaging, ultrasonic welding, laser welding, helium leak testing, hi-pot testing, and X-ray inspection. Drive process characterization, root-cause analysis (5 Whys, 8D, DMAIC), DOE, SPC, GD&T, and statistical validation to achieve process capability, high yield, and low downtime
• Partner cross-functionally with R&D, Ramp, Quality, Maintenance, Automation, and vendors to introduce new cell designs/materials, standardize handover procedures, and close outliers. Optimize cell handling, vision inspection, and joining systems for speed, precision, and repeatability
• Design and integrate advanced automation (PLCs, motion control, real-time data, error-proofing), sophisticated vision systems (Keyence/Cognex), and pneumatic/mechanical/electrical systems (Bluebeam/AutoCAD/Eplan). Develop safety solutions and culture aligned with OSHA, ISO, TUV, NFPA-70E, and IEC standards
• Lead multidisciplinary projects (NPI, CAPA, RCA, OCAP) that integrate automation, predictive analytics, and quality systems (PFMEA/DFMEA, risk assessments). Mentor teams, apply Agile/OKRs, and drive improvements in safety, people, accuracy, rate, and cost
• This role sits at the intersection of process development, equipment qualification, and production ramp, giving you direct influence on how new and existing systems come online and stay capable

What You'll Bring

• Degree or Equivalent Experience in Mechanical, Manufacturing, Chemical, Materials, or Electrical Engineering (or equivalent experience) plus 5+ years in process/equipment development, preferably in lithium-ion batteries/energy storage, electronics, medical devices, automotive, or hermetic packaging. Hands-on lithium-ion cell design, assembly, testing, failure analysis, and R&D-to-production transfer. Demonstrated application of engineering fundamentals to manufacturing scale-up, including dry-room operations with dew-point control, ISO 7/8 cleanroom particle/contamination management, and electrolyte handling at ppb moisture levels
• Proven skills in DFM, equipment/tooling specification and validation, yield/cost optimization, automation integration, project management, and cross-functional collaboration. Proficiency with CAD (SolidWorks/AutoCAD/Eplan), GD&T, fixture/tooling design, statistical tools (DOE, SPC, Cpk/Ppk, Minitab/JMP), PFMEA, control plans, MSA/GR&R, IQ/OQ/PQ, FAT/SAT, Lean/Six Sigma, safety/EHS, MES/Industry 4.0 data systems, troubleshooting, and continuous improvement
• Deep technical expertise treating joining and inspection as an integrated chain: Metal forming/press-fit/swaging (interference fits, plastic deformation, force/displacement, springback, tooling/die design, press selection, in-process monitoring, common failure modes, DFM)
• Ultrasonic welding (polymer and/or metal weldability, joint/horn/anvil design, parameter windows, equipment troubleshooting, strength/hermeticity validation)
• Laser welding (fiber/disk/pulsed systems, beam delivery, thermal/HAZ control, similar/dissimilar metals and plastics, in-process monitoring, safety, and inspection)
• Complementary NDT: helium leak testing (vacuum methods, sensitivity, fixtures, GR&R), hi-pot testing (electrical safety standards, automation, failure modes), and X-ray/CT inspection (radiation safety, defect algorithms, 2D/3D, AI-assisted analysis). Emphasis on equipment specification, vendor management, automation/robotics, simulation, and closing the loop with DFM/DFR for hermeticity, electrical integrity, and internal quality
• Leadership experience guiding mid-to-large multidisciplinary teams, mentoring others, and delivering company-wide impact. Comfort with Agile, OKRs, and high-performing, fast-changing environments. Strong problem-solving, decision-making, and ability to manage multiple priorities under shifting requirements

Benefits

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
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)