Job Description
Welding Process Engineer
Posted on 05/08/2025
Location
Waukesha, WI
Description
Midwest Engineered Systems Inc. (MWES), a leader in welding automation and additive manufacturing, is seeking a Welding Process Engineer for their R&D team in Waukesha, Wisconsin. This role focuses on developing and optimizing advanced welding processes, including robotic MIG welding, laser welding, and Laser Wire Direct Energy Deposition (DED) under the ADDere brand.
Major Duties & Responsibilities
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
Welding Process & Robotic Automation
- Develop, program, and optimize robotic welding systems (preferably ABB and FANUC) for R&D applications.
- Implement and refine Arc Welding processes such as Fronius CMT to enhance weld quality, efficiency, and repeatability.
- Leverage laser welding and laser hybrid welding techniques to optimize deposition rates, material properties, and component performance.
- Troubleshoot robotic welding automation and ensure systems are running at peak performance.
Additive Manufacturing (ADDere – Laser Wire DED)
- Work on the ADDere Laser Wire Direct Energy Deposition (DED) process, assisting in machine optimization and process refinement.
- Support both printing machine development and printing services, ensuring high deposition rates for large-scale metal components.
- Collaborate with customers and internal teams to develop custom additive manufacturing solutions for aerospace, defense, and industrial applications.
- Conduct process validation, quality control, and parameter development for high-deposition additive manufacturing.
R&D Testing & Process Development
- Lead welding and additive process development efforts in our R&D test lab.
- Design and execute testing protocols to evaluate new materials, welding techniques, and deposition strategies.
- Analyze weld integrity, porosity, microstructure, and mechanical properties to improve process reliability.
- Document findings, create reports, and present process improvements to key stakeholders.
Collaboration & Continuous Improvement
- Work closely with engineering, production, and quality teams to integrate new welding and additive processes into manufacturing workflows.
- Provide technical support and training to operators, engineers, and sales teams on robotic welding and additive manufacturing technologies.
- Stay ahead of industry advancements in robotic welding, additive manufacturing, and laser-based welding technologies.
Minimum Skills & Abilities
- Strong problem-solving and analytical skills to troubleshoot welding and additive processes.
- Excellent communication and collaboration skills to work across departments.
- Ability to manage multiple projects in a fast-paced R&D environment.
Minimum Education & Experience
- Bachelor’s degree in Welding Engineering, Mechanical Engineering, Manufacturing Engineering, or a related field (or equivalent experience).
- Robotic Welding: Exposure to ABB RobotStudio and FANUC Roboguide programming.
- Arc welding process: Understand of arc welding process and parameters. Familiar with GMAW, GTAW, and advanced technology associated with each, such as Fronius CMT, Miller Hercules, and Lincoln STT.
- Laser Welding & Hybrid Welding: Familiarity with developing and optimizing laser and laser hybrid welding processes.
- Additive Manufacturing: Familiarity with Laser Wire DED (Direct Energy Deposition) processes
- Process Optimization: Ability to analyze welding defects, develop welding parameters, and improve deposition rates.
- Quality Control: Experience with weld inspection, NDT techniques (X-ray, ultrasonic, metallography), and material analysis.
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