Manufacturing Joining Engineer, Closures at Tesla in Austin, TX

Tesla is seeking a highly motivated and experienced Manufacturing Joining Engineer to join our Closures team supporting NV93 GA Closures. As the plasma, 2K dispense, bonding, and vision specialist, you will own process health, equipment performance, and continuous improvement for automated joining of plastic closure assemblies. You will maintain and improve existing processes, tooling, and robotic cells, and partner with cross-functional teams to remove bottlenecks and raise line performance.

Responsibilities

• Serve as the subject matter expert for Plasma surface treatment, SCA Dispensing 2K, structural Bonding, and Vision Systems (Coherix + Mech Mind) across NV93 GA Closures
• Own day-to-day process stability for plasma treatment quality, 2K mix/bead/path control, bonded-joint integrity, and in-process vision (Coherix bead/Z-tracking and Mech Mind 3D)
• Perform root cause analysis on complex joining faults (plasma coverage/dyne, mix ratio, open time, wet-out, adhesion vs cohesive failure, bead geometry, compression/fit-up, vision false rejects) using DMAIC, Ishikawa, Five Why (5W), and Eight Disciplines (8D), and drive permanent corrective actions
• Lead production trials to optimize plasma, 2K dispense, and bonding parameters, introduce new product designs, and validate process windows on plastic-to-plastic and plastic-to-metal joints
• Analyze production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE); optimize cycle time, balance workloads, and reduce bottlenecks in plasma, dispense, bonding, and vision stations
• Lead non-conforming material (NCM) activities, including rework procedures, containment, and line fallout troubleshooting for bonded closures; support manufacturing excellence (5S, Lean, material handling, line layout)
• Monitor and reduce process variation using SPC and Measurement Systems Analysis (MSA), including dyne/surface energy, bead volume/height, teardown CF%, max defect length, and vision system capability
• Develop and maintain process sheets, PFMEAs, control plans, and standard operating procedures for plasma, 2K dispense, bonding, and vision
• Apply GD&T and plastics manufacturing knowledge to diagnose fit-up, gap, compression, locator, and dimensional stack-up issues that drive bond quality on molded closure assemblies
• Partner with Controls, Maintenance, Quality, Materials, and equipment vendors (SCA, Coherix, Mech Mind, plasma OEMs) on upgrades, spare strategy, and technical escalations

Requirements

• Degree in Mechanical, Mechatronics, Automotive, Manufacturing, Materials/Polymer, or equivalent experience
• Background in plastics manufacturing processes required (injection molding, dimensional stability, surface energy, primer/adhesion promoters, thermal expansion of plastic assemblies)
• Background in Geometric Dimensioning and Tolerancing (GD&T) required
• 4+ years developing and improving high-volume manufacturing processes; at least 2+ years hands-on in plasma treatment, 2K adhesive dispensing, and/or structural bonding of plastic assemblies in automated/robotic environments
• Strong knowledge of plasma fundamentals (surface energy, dyne, treatment distance/speed/power, coverage), 2K dispense (mix ratio, pot life/open time, bead path, volume/height control), bonding (wet-out, compression, cure, cohesive vs adhesive failure, tensile/peel), 3D vision (Coherix / Mech Mind), and joining quality gates (teardown CF%, max single-defect length)
• Ability to initiate design and process changes using DfM, Poka-Yoke, and failure-mode elimination
• Strong understanding of BOM, MES, quality specifications, process capability (Cpk), and change management
• Ability to use structured problem-solving (DMAIC, Ishikawa, 5W, 8D) and to collaborate with cross-functional teams on highly technical problems
• Excellent written and verbal communication skills
• Linux, Tableau, SQL, Ignition, and/or Minitab experience preferred; exposure to other Closures joining technologies (ultrasonic spot weld, 1K urethane/SCA SG10, Robotape, sealing) is a plus

Compensation and benefits