Systems Engineer, Optimus Robot Design Validation

What to Expect

Tesla is looking for a highly motivated Systems Engineer to validate the fidelity of manufactured Optimus robots to design intent and modeling from a kinematics, dynamics, and sensing perspective. You will work across cross-functional teams to develop and execute validation methodologies that ensure accuracy, precision, and repeatability at high volume - directly driving design improvements and closing the loop between simulation and real hardware. If you have a strong foundation in mechanical systems, metrology, and robotics, and a track record of translating physical measurements into actionable design changes, join Tesla to play a pivotal role in shaping the future of AI robotics.

What You’ll Do

• Work closely with Hardware, Software, and Simulation teams across the full product lifecycle - from initial concept and prototype builds through high-volume production to validate that manufactured robots conform to design intent and URDF specifications
• Validate robot link dimensional accuracy, mass properties, and range of motion using metrology tools including FARO arms, FARO laser trackers, CMM, structured light and laser 3D scanners, and fixture-based gauging, confirming production hardware matches CAD within tolerances
• Validate kinematic accuracy of differential linkages and joint mechanisms by measuring hardware across multiple poses and correlating expected versus measured angles, with and without load
• Develop and validate bot-level end effector and joint error models incorporating mechanical tolerances, calibration accuracy, backlash, datum variation, and vision system errors - validated on real hardware using Opti Track, Vicon motion capture, FARO metrology, and fixture-based testing
• Feed production measurement data - including end effector errors, joint errors, stiffness, backlash, and friction - back to simulation and modeling teams to improve sim-to-real performance
• Develop and validate high-volume joint encoder calibration methodologies compatible with production cycle times, including end-stop, gauge block, fixture-based, vision-based, and IMU-based approaches
• Characterize calibration accuracy and repeatability across the robot fleet, exposing hardware design and quality issues that drive calibration errors and feeding findings back to design teams
• Design and execute validation studies - including GR&R studies, degradation studies, and fixture-based checks - to systematically identify and root cause kinematic and dynamic performance issues across robot generations
• Translate validation findings into concrete design change recommendations, partnering with Design Engineering to drive hardware improvements that improve accuracy, repeatability, and yield across the fleet
• Define and maintain validation test plans, metrology protocols, and documentation standards to support continuous improvement as the Optimus platform scales to high-volume production

What You’ll Bring

• Degree in Engineering, or equivalent experience
• Proficiency in CAD tools (CATIA and AutoCAD preferred) and ability to interpret and validate against engineering drawings and URDF specifications
• Hands-on experience with metrology equipment including FARO arms, FARO laser trackers, CMM, structured light and laser 3D scanners, Opti Track, and Vicon motion capture systems
• Proficiency in mechanical assembly and familiarity with joint mechanisms, linkages, fastener selection, and harness integration
• Proficiency in electrical integration, testing, and troubleshooting, including familiarity with communication protocols and control systems
• Experience designing and executing structured validation studies including GR&R, tolerance stack-up analysis, and Monte Carlo simulation
• Experience with robotics simulation platforms such as Mu JoCo or Isaac Lab, and familiarity with robotics kinematics, URDF modeling, and sim-to-real validation concepts
• Experience transitioning products from prototype to production with a focus on measurement systems, process capability, and quality
• First-principles problem-solving mindset with a strong ability to connect physical measurements to root cause and design action
• Able to work under pressure while managing competing demands and tight deadlines using exemplary verbal and written communication skills; well-organized with meticulous attention to detail