DGM - Laser & Ultrasonic Welding

About the role

The Laser & Ultrasonic Welding Subject Matter Expert supports the Global Manufacturing Engineering team in developing, industrialising and continuously optimising advanced joining processes for cell manufacturing. The role ensures that all welded and bonded connections meet required mechanical, electrical and safety performance through robust parameter definition, validation and disciplined process control.

Key responsibilities

• Develop, industrialise and optimise laser welding processes for cell cans, tabs, busbars and current collectors, defining parameter windows, weld schedules and standard work.
• Specify, validate and optimise ultrasonic welding processes for electrode tab welding, busbar connections and foil joins, including tool design, horn/anvil selection and stack maintenance.
• Participate in PFMEA, control‑plan creation and process‑capability studies (Cp/Cpk) for all welding operations; define critical‑to‑quality (CTQ) features and acceptance criteria.
• Lead trials, Design of Experiments (DOE) and correlation studies linking weld parameters with NDT results (vision, X‑ray/CT) and destructive testing.
• Collaborate closely with equipment, quality, maintenance and production teams to drive weld quality, yield improvements and high‑takt, high‑reliability production.

Required profile

• Bachelor’s degree in Mechanical Engineering or equivalent demonstrable experience; OEM experience may substitute.
• Strong background in laser welding (e.g., Trumpf, IPG) and ultrasonic welding for metals, preferably in batteries, automotive or electronics.
• Experience with weld quality assessment (macro etch, cross‑section, pull/shear testing) and NDT integration (vision, X‑ray).
• Familiarity with joining Cu, Al, Ni and coated foils and understanding of metallurgy and heat‑affected zones in thin materials.
• Preferred certifications: AWS C7.4/C7.4M Laser Beam Welding Operator Qualification, ISO 15609‑4 Laser Welding WPS Certification, ASNT UT Level I/II, ISO 9712 Certified NDT Technician – Ultrasonic Testing.

Required skills

• Laser welding (Trumpf, IPG)
• Ultrasonic welding
• Weld quality assessment (macro etch, cross‑section, pull/shear testing)
• Non‑destructive testing (vision inspection, X‑ray/CT)
• PFMEA and control‑plan development
• Process capability analysis (Cp, Cpk)
• Design of Experiments (DOE)
• Parameter and CTQ definition
• Equipment commissioning
• Tool design (horn/anvil selection) and stack maintenance
• Metallurgy of Cu, Al, Ni and coated foils
• Heat‑affected zone analysis