Staff Mechanical Design Engineer, Electrical Safety Devices

What to Expect

Join a fast-paced team designing cutting edge High Voltage & High Current electrical safety devices for use across the entirety of Tesla. From Vehicle and Energy Storage to Supercharging and Manufacturing, the HV Devices team looks beyond traditional devices like sealed contactors, fuses, and pyrotechnic breakers. One example is the Cybertruck ‘DPDT’ – a motor-actuated reconfigure contactor capable of conducting high charging current, withstanding high voltages, and actuating reliably for thousands of cycles.

You will lead efforts to push new devices to new levels, improving integration, efficiency, safety/performance, manufacturability, mass, and cost. Our work is highly multi-disciplinary and, in addition to mechanical fundamentals, you are expected to know or learn basic electrical and magnetic physics. At Tesla, design doesn't stay on a screen, and we don't waste time on products for which we do not see a future. If a first-principles mindset energizes and excites you, this is your chance to turn abstract ideas into real-world technologies that millions will rely on — built and shipped in industry-record time while setting new industry standards.

Roles are available at multiple seniority levels (Senior, Staff, Sr. Staff, etc.) based on experience

What You’ll Do

• Identify key areas for technology development in HV Safety Devices, focusing on innovative solutions that improve efficiency, elevate voltage and power capabilities, reduce footprints, and enable high volume manufacturability – over 1 million units per year
• Apply creative, first-principles-based problem solving to generate groundbreaking solutions that address complex engineering challenges
• Conduct multi-physics simulations and optimizations to refine designs, ensuring they meet rigorous performance, thermal, structural, and environmental requirements
• Collaborate with cross-functional teams, including electrical hardware, firmware, thermal, and manufacturing teams to integrate designs into broader HV architectures
• Develop detailed engineering test plans, prototype builds, and validation strategies to meet truncated program timelines from ideation to high volume production with confidence
• Oversee the modeling and design of electro-mechanical components such as solenoids, motors, HV insulation, HV interruption devices while solving packaging issues like thermal management, vibration and shock, footprint reduction, interconnection, and ingress protection
• Create comprehensive drawing packages, manufacturing instructions, and assembly processes to support rapid prototyping and scalable production

What You’ll Bring

• 8+ years of experience in mechanical design / related field OR demonstrated technical excellence in product design & analysis, with a proven track record of bringing products to high volume production on-time and meeting key yield & cost targets
• Exceptional creativity and solid foundation in first principles thinking, enabling you to devise novel solutions that push the boundaries of what is possible
• Outstanding organization, written, and verbal communication skills to collaborate effectively, leading projects with diverse stakeholders. This is a high impact role where you are expected to rally an organization and its leaders around your ideas
• Expertise in multi-physics simulations (e.g., structural, thermal, kinematic, electrical, magnetic systems), optimizations, navigating system-level trade-offs and informing device design direction
• Extensive knowledge of various manufacturing techniques, including injection molding, stamping, die casting, fastening & joining, welding & bonding, dispensing, and automation to make sure designs are high volume production ready
• Strong mechanical engineering fundamentals, knowledge of GD&T, tolerance stacks, design for manufacturing/automation/test/reliability, including DFMEA
• Proficiency with tools like CATIA V6 3DExperience, MATLAB/Simulink or Python, ANSYS or similar
• Experience with environmental, reliability, safety, and industry standards for automotive, industrial, or residential products
• Familiarity with PCBAs, PCBA components, battery management systems, electrical bussing, relays, fuses, contactors, switchgear, solenoids, and/or electric motors