Manufacturing Engineer, Back-End Cell Assembly

About the role

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.

Responsibilities

• 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.

Requirements

• 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 (including cell design input on fill ports and sealing features), equipment/tooling specification/qualification/validation (IQ/OQ/PQ, FAT/SAT), yield/cost/cycle-time optimization, automation integration, project management, and cross-functional collaboration