Manufacturing Engineer, Front-End Cell Assembly

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.

- 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

- 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