Manufacturing Engineer - Welding

POWER ELECTRONICS | AUTOMATION | PROCESS & EQUIPMENT DEVELOPMENT WHAT TO EXPECT Heron Power is a startup company building cutting-edge power electronics for the 21st-century grid. We aim to debottleneck the growth of electricity generation and consumption with scalable, innovative, and less costly hardware solutions, accelerating the electrification of everything. Our first goal is to build better converters (inverters & rectifiers) to connect large-scale renewables, storage, and loads to the grid. Heron’s leadership team is made up of seasoned veterans who have designed and shipped gigawatts of power conversion products over the past decade. We understand that no one individual knows everything. We will all learn a lot together and from each other. We strive to build a collaborative, enriching environment conducive to personal, technical, and career growth. You can expect to work in a dynamic and collaborative environment, driven by first principles engineering, solving difficult problems. JOB OVERVIEW As a Manufacturing Engineer - Welding (Advanced Processes), you will be responsible for developing, testing, deploying and scaling high volume manufacturing for our power electronics assemblies. This role will be responsible for some of our most exciting and complex manufacturing technologies and will lead process and equipment development for advanced automation/robotics, chemical handling systems associated with thermal interface materials and thermal gap fillers, plastics/metals assembly, and surface treatments. You will work closely with product, mechanical and electrical design teams early and often through DFM, design processes from a first principles approach and close the feedback loop to ensure both the product and the lines that make it are robust. You will collaborate closely with external suppliers and equipment partners to land scalable, reliable and highly repeatable equipment lines and processes, owning them from concept to production ramp. HOW YOU WILL CONTRIBUTE - Develop, scale, and optimize welding processes: ultrasonic, laser, vibration, brazing, and hybrid methods - Specify and commission high-speed welding equipment and automation - Integrate welding processes with conveyors, robots, and inline inspection systems - Conduct FAT/SAT, validation, and process qualification for pilot and production lines - Define process windows using DoE, PFMEA, SPC, and structured problem-solving - Troubleshoot welding defects and drive continuous improvement - Collaborate with suppliers and OEMs for equipment development and ramp readiness WHAT YOU WILL BRING Must-Haves - Bachelor’s in Mechanical, Manufacturing, Industrial, Electrical, or related Engineering - 7+ years in welding process development or automation in industrial/manufacturing settings - Hands-on experience with ultrasonic, laser, or vibration welding - Experience with automation, robotics, PLCs, and inline inspection systems - Strong first-principles engineering and troubleshooting skills - Experience with PFMEA, SPC, DoE, GD&T, and precision assembly Nice-to-Haves - Experience in power electronics, EV, or aerospace assemblies - Supplier development and industrialization experience If you are passionate about technology and enjoy working in a fast-paced environment, we would love to hear from you. Join us in accelerating the electrification of everything at Heron Power. Heron Power provides competitive compensation (salary and equity) and benefits. The salary for this role ranges from $150,000 to $200,000 per year.