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Senior Process Engineer - Ultrasonic Welding Specialist

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Aptiv plc

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Job Description:

As a Senior Process Engineer specializing in Ultrasonic Welding (USW), you will be a key technical expert within the Manufacturing Excellence Center of Aptiv. You'll leverage your advanced USW knowledge to design, implement, and continuously improve ultrasonic welding manufacturing processes that increase efficiency, reduce costs, and enhance product quality while ensuring compliance with Aptiv's internal procedures.

Job Responsibility:

  • USW Process Leadership: Lead the development and optimization of ultrasonic welding processes across Aptiv's manufacturing facilities with minimal supervision, serving as the company's foremost USW technical authority
  • Technical Documentation: Develop and maintain comprehensive engineering documentation for ultrasonic welding processes, including weld specifications, process parameters, and qualification protocols
  • Prototype Development: Coordinate USW prototype builds from concept to production, establishing critical weld parameters and validating joint integrity
  • Process Analysis & Optimization: Conduct in-depth analysis of ultrasonic welding results using advanced measurement techniques, implement process improvements, and optimize weld parameters for various materials and joint designs
  • Component Quality Assessment: Provide expert evaluation on the weldability of components and materials, recommending design modifications to enhance USW compatibility
  • Risk Management: Contribute specialized USW expertise to DFMEA/PFMEA development, identifying specific risks associated with ultrasonic welding processes
  • Cost Estimation: Develop detailed quotes for USW equipment and processes, including specialized tooling, fixtures, and process monitoring systems
  • Technical Reporting: Review and interpret USW test reports with advanced analytical skills, drawing conclusions and implementing sophisticated process adjustments
  • Equipment Qualification: Lead comprehensive machine tests, benchmarking, and qualification protocols specifically for ultrasonic welding equipment
  • Test Development: Define new USW test requirements and procedures to ensure weld quality, strength, and reliability across various applications
  • Problem Resolution: Lead complex problem-solving activities related to ultrasonic welding challenges, applying root cause analysis methodologies
  • Knowledge Management: Maintain and expand the company's USW knowledge base through BOD, BOP documentation and lessons learned
  • Analytical Excellence: Utilize advanced analytical tools including weld quality monitoring systems, tensile testing, metallographic analysis, and statistical process control
  • Standards Compliance: Ensure USW processes comply with Aptiv standards and Customer Specific Requirements for welded connections
  • Technical Specification Development: Lead the development of technical specifications for new USW devices, fixtures, and monitoring software
  • Technical Training: Develop and conduct comprehensive training programs on USW technologies for manufacturing personnel
  • Supplier Collaboration: Partner with USW equipment suppliers to develop custom solutions and process improvements
  • Technology Advancement: Continuously research emerging USW technologies and techniques, evaluating their potential application in Aptiv's manufacturing processes

Requirements:

  • B.S or M.S in technical field Mechanics or equivalent, Industrial background (Materials engineering is a plus)
  • 1 to 3 years experience in a similar position
  • Fluent in English
  • Experience in the use of Microsoft Office applications
  • Ability to plan and prioritize own task
  • Ability to read technical drawings & documentation
  • Ability to travel across EMEA up to 30%
What we offer:
  • You can grow at Aptiv. Aptiv provides an inclusive work environment where all individuals can grow and develop, regardless of gender, ethnicity or beliefs.
  • You can have an impact. Safety is a core Aptiv value
  • we want a safer world for us and our children, one with: Zero fatalities, Zero injuries, Zero accidents.
  • You have support. We ensure you have the resources and support you need to take care of your family and your physical and mental health with a competitive health insurance package.

Additional Information:

Job Posted:
February 19, 2026

Employment Type:
Fulltime
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