Sr. Laser Process Development Engineer

About the role

• Sr. Laser Process Development Engineer | Tesla (Manufacturing)
• Location: Fremont, California | Req ID: 259441 | Job Type: Full-time
• What to Expect

Tesla is seeking a highly motivated Senior Laser Process Engineer to develop, engineer and innovate new laser processes and high-volume automation equipment with the cell manufacturing team in Fremont, CA. Specifically, this engineer is expected to be (or become) a process expert in the field of laser welding & cutting applications, including work in both lab environment and transfer of processes to high volume manufacturing.

You will take ownership of new process development and process optimization for pilot-scale and mass production equipment - leading experiments, data analysis, and process characterization. You will also support the technical transfer of processes and tools to production, ensuring they meet the highest standards of safety, quality, and throughput.

You will work closely with internal teams including Product Design, Controls, Operations, Quality, and Production Engineering and will coordinate with equipment suppliers to develop scalable innovations in laser processes and tools. This role will be based in Fremont, CA but would function as a global expert of these systems, so some international travel will be required.

What You'll Do

• Develop novel laser processes and select laser process equipment
• Design and execute experiments to evaluate and optimize laser processes
• Analyze process data to identify key parameters, trends, and equipment performance
• Develop hypotheses and theories to explain observed process phenomena and validate them through structured experimentation
• Perform measurement system analysis (e.g., Gage R&R, bias, linearity) to ensure inspection reliability
• Support design, commissioning, and validation of pilot and production equipment
• Manage installation, qualification and ramp-up of manufacturing equipment including (but not limited to) systems with laser processes
• Collaborate with Production Engineering, EH&S, Quality, Operations and Product Design team drive towards maximum yield, quality, machine availability and output
• Generate machine specifications, documentation, and manufacturing instructions

What You'll Bring

• Degree or Equivalent Experience in Mechanical Engineering, Mechatronics, or related field
• 6+ years of experience developing processes for pilot and high-volume manufacturing
• Experience working with laser processes, equipment, and relevant metrology systems
• Demonstrated ability to design and execute experiments, analyze data, and apply structured problem-solving (DOE, FMEA, 5-Why)
• Proficiency with SolidWorks or other 3D CAD software
• Proven track record of data-driven workflow to solve complex problems
• Hands-on experience with automation, sensors, and PLC-controlled equipment
• Strong mechanical aptitude, analytical mindset, and ability to translate observations into scalable process improvements

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)

Expected Compensation$91,600 - $164,400/annual salary + cash and stock awards + benefitsPay 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.