Sr. Weld Engineer

Key Duties and Responsibilities

• Develop, optimize, and characterize resistance welding process windows using structured DOE methodologies, including analysis of expulsion limits, electrode wear behavior, and design improvements.
• Apply Design for Manufacturing (DFM) principles to enhance producibility, reliability, and robustness of welded assemblies for spaceflight hardware.
• Partner closely with manufacturing teams and technicians to implement welding process plans, operating procedures, and standardized work instructions.
• Interpret industry welding standards and tailor them to Terran Orbital applications to support WPS and PQR creation and maintenance.
• Develop, qualify, and maintain weld schedules for resistance welding equipment used in battery and power storage system production.
• Collaborate with Quality Engineering to establish pass/fail criteria across battery cell and module weld operations, and lead disposition, root cause analysis, and corrective actions for weld-related nonconformances.
• Drive cross-functional initiatives to improve manufacturing reliability, implement poke-yoke strategies, and reduce variation across production lines.
• Clearly communicate, justify, and defend engineering decisions using a data-driven, fact-based approach suitable for flight-critical hardware.
• Contribute to continuous improvement activities, including equipment capability studies, weld tool design enhancements, and advanced welding technique evaluations.
• Support the development of next-generation welding processes and battery technologies for spacecraft power systems.

Required Qualifications and Skills

• BS in Welding Engineering, Mechanical Engineering, Industrial Engineering, or related discipline.
• 5+ years of experience with welding materials and processes, including parallel gap resistance spot welding.
• Strong understanding of weld parameter development, metallurgy, and weld joint design; ability to assess tradeoffs between welding methods for aerospace applications.
• Experience with robotic welding systems and automated welding integration.
• Demonstrated ability to develop and qualify resistance weld profiles for battery cells and battery structural components.
• Proficiency with root cause analysis methodologies (e.g., 5 Whys, fishbone, fault-tree analysis) and corrective action implementation.
• Familiarity with CAD tools and ability to interpret complex engineering drawings and GD&T.
• Background in materials science or metallurgical behavior of weld joints preferred.
• Demonstrated ability to operate outside comfort zones, innovate, and contribute to the advancement of space-based power storage technologies.
• U.S. Person or lawful permanent resident to comply with U.S. government space technology export regulations.

Benefits

• 100% Company-paid comprehensive medical, dental, and vision coverage for you and your dependents
• 401(k) Match
• Flexible Time Off (FTO)
• Education Reimbursement
• Competitive Paid Parental Leave

Pay

Salary Range: $125,000 USD - $170,000 USD. Your actual level and base salary will be determined case-by-case and may vary based on the job-related qualification, knowledge, skills, education, and experience.

About Terran Orbital

Terran Orbital is a leading manufacturer of satellite products primarily serving the aerospace and defense industries. Terran Orbital provides end-to-end satellite solutions by combining satellite design, production, launch planning, mission operations, and on-orbit support to meet the needs of the most demanding military, civil, and commercial customers. Learn more at www.terranorbital.com