Electrical Engineer - High Voltage Micro-Welding Systems

Why Dakkota

For over 24 years, Dakkota Integrated Systems has delivered excellence through precision-engineered, build-to-order vehicle components from cockpits to fascia assemblies. Our award-winning team combines advanced lean manufacturing, strong product development, and a highly efficient supply chain to meet customer demands with reliability and innovation.

If you're looking for a company that empowers you to grow while driving excellence, collaboration, and innovation to create real impact, we’d love to meet you.

The role

We are seeking a strategic and dynamic Electrical Engineer – Micro‑Welding Systems with High Voltage Applications to lead the support of designing, integration, optimization, and ongoing of electrical and control systems for advanced micro‑welding technologies used in EV battery manufacturing. This role is responsible for delivering safe, repeatable, and high‑quality welding solutions for high voltage flex circuit that supports battery cells, modules, and packs in high‑volume production environments.

The ideal candidate is an innovative, data‑driven engineer with a passion for advanced manufacturing, electrical safety, and process excellence, who thrives in fast‑paced EV launch environments and actively contributes to a culture of continuous improvement and operational growth. This position is a hybrid role based in the greater Detroit, Michigan area and reports to the Corporate Senior Reliability Manager as part of the Corporate Engineering team.

What You’ll Do

Electrical & Controls Engineering

• Support tool shop design, specify, and troubleshoot electrical and control systems for high voltage flex circuits with micro‑welding equipment, including laser and resistance welding platforms.
• Support tool shop creation and maintain electrical schematics, panel layouts, wiring diagrams, and I/O documentation to support automated flex circuit manufacturing systems with tool shops
• Support tool shop integration of PLC platforms, motion control systems, laser controllers, HMIs, safety PLCs (Allen Bradley, Siemens), and industrial communication networks (EtherNet/IP, Profinet, Modbus).
• Ensure compliance with applicable electrical and safety standards, including NFPA 79, IEC, UL, and internal high voltage manufacturing requirements.

High Voltage Flex Wire Harness Welding Process Support

• Provide electrical and controls support for micro‑welding processes used in battery tabs, busbars, cell‑to‑cell, voltage sense tabs, and module interconnects.
• Support welding of copper, aluminum, nickel, and plated materials, including dissimilar metal joints common in EV battery assemblies.
• Interface with laser sources (fiber and disk), beam delivery optics, galvo scanning systems, wavelength (Blue, Red, Green), and resistance welding power supplies.
• Implement and support real‑time weld monitoring and feedback systems, including current, voltage, energy, displacement, plume monitoring, vision inspection, and pyrometry.
• Support weld validation and quality requirements in accordance with ISO 13919, ISO 6520, AWS standards, and customer‑specific battery specifications.

Battery Safety & Compliance

• Support electrical safety requirements for high‑energy EV battery manufacturing environments.
• Support the Design to implement and validate laser safety systems, including Class 4 laser enclosures, interlocks, LOTO, light curtains, and safety PLC architectures.
• Ensure proper grounding, isolation, and ESD controls critical to safe battery production.
• Support compliance with IATF 16949, ISO 9001, and customer‑specific EV battery safety and quality requirements.

Manufacturing, Launch & Commissioning Support

• Lead electrical Laser welding engineer supporting equipment commissioning, FAT/SAT activities, production line launches, and ramp‑up.
• While launching through SORP, provide hands‑on troubleshooting to minimize downtime, scrap, and weld‑related defects in high‑volume manufacturing environments from a launch perspective.
• Launch lead supporting driving continuous improvement initiatives focused on OEE, First Pass Yield (FPY), defect reduction, and equipment reliability.
• Collaborate with maintenance teams to develop preventive maintenance standards, electrical troubleshooting guides, and training materials.

Quality, Traceability & Data Systems

• Support creation of PFMEA, DFMEA (as applicable), Control Plans, and process capability (Cp/Cpk) related to EV battery welding processes.
• Implement initial launch weld data collection, traceability, and process monitoring tied to serial numbers, and MES systems.
• Participate in structured problem‑solving efforts (8D, A3, root cause analysis) involving weld defects, reliability issues, or field concerns.
• Support PPAP submissions, customer audits, and launch readiness reviews for EV battery programs.
• Support VAA new program and launch initiatives and perform additional responsibilities as required.

Cross‑Functional & Supplier Collaboration

• Work closely with Battery Process, Mechanical, Automation, Quality, and Reliability Engineering teams to ensure robust welding systems.
• Interface with laser OEMs, welding equipment suppliers, integrators, and vision system vendors to support system development, debugging, and optimization.
• Provide technical support to global EV battery manufacturing sites as required.

Who you are

• Bachelor’s degree in Electrical Engineering, Mechatronics, or related field.
• 5+ years of electrical engineering experience in automotive or EV battery manufacturing.
• Hands‑on experience with laser and/or resistance micro‑welding systems in automated, high‑volume production.
• Proficient with electrical design tools (EPLAN, AutoCAD Electrical), PLCs (Allen‑Bradley and/or Siemens), and industrial networks (Profinet, EtherNet/IP).
• Experience with laser systems, welding power supplies, safety systems, functional safety, weld monitoring, vision, and data acquisition.
• Strong analytical, troubleshooting, and data‑driven problem‑solving skills with a high focus on detail and safety.
• Effective cross‑functional communicator able to support fast‑paced EV launch environments.
• Cross-functional communication

Preferred Qualifications

• Experience supporting EV battery cells, modules, and/or pack manufacturing.
• Understanding of Battery Architecture for different formats of cells (prismatic, cylindrical and pouch)
• Understanding of criticality of functions of Current Collector Assemblies.
• Knowledge of battery tab micro‑welding, including Cu‑Al, Cu‑Ni, and Al‑Al joints.
• Laser safety certification and/or experience managing Class 4 laser systems.
• Experience with MES integration, weld traceability, and weld data analytics.

Health, Safety, Physical & Travel Requirements

• Ability to sit or stand for extended periods and move throughout office, and manufacturing environments.
• Required travel up to 75% domestically.
• Capable of working on the manufacturing floor and in controlled EV battery production environments.
• Ability to support equipment installation, commissioning, and onsite troubleshooting activities.
• Proficient in daily use of computers and standard office equipment.

Life at Dakkota

Our success is rooted in meaningful relationships and a culture that feels like family. We champion compassion, respect, and work-life balance, while supporting each team member’s personal and professional growth. Through ongoing development, competitive pay, and a comprehensive benefits package, we empower our people to thrive both at work and in life.

Our benefits include paid time off, medical, dental, and vision coverage, and a 401(k) plan for eligible employees.

Explore everything we have to offer at Dakkota Careers!