Sr. Mechanical Design Engineer, Energy Infrastructure, Power Electronics

What to Expect

Energy will be the heart that fuels an AI future of amazing abundance. AI datacenters, vehicle and robot charging at scale are colliding with grid capacity. Tesla Energy must supply all three. As a Mechanical Design Engineer in Power Electronics, you will design the converters, magnetics, insulation, and thermal systems that move energy into, out of, and through Tesla’s storage and grid products. This is full-stack mechanical work on high-power electronics: packaging, isolation, heat, vibration, and high-volume manufacturing, owned from blank page to production.

You will join an elite team of driven engineers with huge scope, reach, and potential impact. Despite the name, Power Electronics pushes the wide breadth of the mechanical engineering field. You are required to know and apply statics and dynamics, fluids and thermals, mechanics and vibration, and more. The work is highly multi-disciplinary, and you are expected to know or learn basic electrical and magnetic physics, material science, and advanced manufacturing techniques.

Strong design skills, a first-principles approach to problem solving, curiosity to learn, and drive to develop are must-haves. At Tesla, design work does not only live on a computer screen. We don’t waste time on products we don’t see a future in. Your designs will come to life in the world within record time. You will drive prototype builds, engineering testing, and validation, owning each design from conception through mass production.

Roles available at multiple seniority levels for those with more experience; Sr., Staff, etc.

What You’ll Do

• Modeling and design of electro-mechanical parts and assemblies including plastics, sheet metal, heat sinks, insulation systems, magnetic components, high voltage connectors, fasteners, and other components
• Mechanical design analysis including thermal, CFD, structural, design for assembly, and design for test
• Collaborate with program stakeholders to integrate designs into energy storage, grid-tied, and related products that supply and condition power for AI infrastructure and Tesla Energy
• Solve electronics packaging issues including: electrical isolation, sealing, thermal management, interconnection, shock and vibration management, electromagnetic interference (EMI), RF communications, etc
• Develop engineering test plans for designs
• Create drawing packages and manufacturing instructions for parts and assemblies
• Assist in engineering prototype builds and component fabrication
• Collaborate with other mechanical, systems, electrical, digital control, manufacturing, industrial design, and test engineers to take designs from prototype through mass production

What You’ll Bring

• 2+ years of experience in mechanical design or related field OR demonstrated technical excellence in product design/analysis
• Strong mechanical engineering fundamentals and physics first principles
• Strong organization, written and verbal communication skills
• Knowledge of GD&T, finite element analysis, and design for reliability concepts
• Experience using CATIA V5 and/or V6. Experience with PLM systems, engineering changes, deviations, BOM structuring, etc
• Working knowledge of MATLAB, Python, ANSYS, StarCCM
• Experience with environmental, reliability, safety, and industry standard requirements for automotive, industrial, and energy products
• Basic understanding of electrical design fundamentals
• Experience with high volume manufacturing and automated assembly processes such as injection molding, stamping, diecast, fastening, dispensing, joining, etc.
• Familiarity with PCBAs and PCBA components