Senior Weld Engineer for Space Battery Power Systems

Terran Orbital Corporation; Irvine (CA); On-site; USD 125,000 - 170,000; Full time

Benefits offered by this job

Medical, dental, and vision coverage

401(k) Match

Flexible Time Off

Education Reimbursement

Job summary

Terran Orbital in Irvine, CA seeks an experienced Sr. Weld Engineer to lead welding process design for high‑reliability space hardware, including resistance spot welding and battery manufacturing for spacecraft.

Reporting to the IPT Lead – EPS, you will develop weld schedules, apply DFM, and collaborate with manufacturing, QA, and engineering to ensure flight‑critical assemblies meet strict standards and contribute to next‑generation power systems.

Qualifications

• 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.
• Experience with robotic welding systems and automated welding integration.
• Ability to develop and qualify resistance weld profiles for battery cells and modules.

Responsibilities

• Develop, optimize, and characterize resistance welding process windows using structured DOE methodologies.
• Apply Design for Manufacturing (DFM) to enhance producibility, reliability, and robustness of welded assemblies.
• Partner with manufacturing teams to implement welding process plans and standardized work.
• Interpret welding standards and tailor them for spaceflight hardware (WPS/PQR creation).
• Develop, qualify, and maintain weld schedules for welding equipment used in battery production.
• Collaborate with Quality Engineering to establish pass/fail criteria and lead corrective actions for weld nonconformances.

Skills

Welding engineering

Mechanical engineering

Resistance spot welding

Robotic welding

Root cause analysis

CAD tools

GD&T interpretation

Materials science

Education

BS in Welding Engineering

Tools

CAD software

GD&T

Job description

Terran Orbital in Irvine, CA seeks an experienced Sr. Weld Engineer to lead welding process design for high‑reliability space hardware, including resistance spot welding and battery manufacturing for spacecraft.

Reporting to the IPT Lead – EPS, you will develop weld schedules, apply DFM, and collaborate with manufacturing, QA, and engineering to ensure flight‑critical assemblies meet strict standards and contribute to next‑generation power systems.