
Tesla
Power Module Mechanical Design Engineer
RoleEngineering
LevelMid Level
LocationPalo Alto, Canada, United States
WorkOn-site
TypeFull-time
PostedToday
About the role
What to Expect
Join the electric revolution as a Mechanical Design Engineer. You'lllead module packaging design end-to-end, from first-principles concept to high-volume production, shaping the technology that powers every vehicle and energy product we ship. Working at the intersection of thermal, mechanical, and electrical engineering, you'll partner with cross-functional teams to push the limits of efficiency, reliability, and scale. Your designs won't just hit a spec sheet, they'll drive the future of sustainable energy, and we're looking for a bold, motivated engineer ready to lead the way.
What You’ll Do
- Own mechanical design and optimization of power modules, balancing thermal, mechanical, electrical, and manufacturing constraints
- Develop packaging solutions with cross-functional teams from requirements through design, validation, and production builds
- Research and introduce new packaging materials and processes (substrates, attaches, encapsulants, interconnects, and beyond)
- Create, release, and control package drawings and design documentation
- Lead or contribute to DFMEA/PFMEA and resolve packaging and assembly issues through root-cause analysis
- Support mechanical tooling design for assembly equipment as designs move into production
- Take modules from prototype through high-volume manufacturing, applying direct experience with SiC or GaN power modules and automotive power electronics / traction inverter packaging where relevant
What You’ll Bring
- Bachelor’s Degree in Mechanical Engineering or equivalent experience
- Master's Degree or Doctorate Degree preferred for candidates with deep packaging or multi-physics backgrounds
- 3+ years of industry experience in power module, power electronics packaging, or closely related semiconductor packaging design
- First-principles mindset across thermal, mechanical, materials, and electrical interactions
- Strong CAD skills (Solid Works, CATIA, or similar) and experience with FEA / multi-physics simulation (ANSYS Mechanical, ICEPAK, Q3D, or equivalent)
- Working knowledge of DFM, DFT, design for reliability, tolerance analysis, and DFMEA/PFMEA
- Familiarity with automotive reliability, environmental, and safety standards
- Hands-on knowledge of electronics packaging materials and processes: ceramics/substrates, solder or sinter attaches, encapsulation, wire bonding, adhesives, copper clip, etc.

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