Sr. Mechanical Design Engineer, Electrical Safety Devices, Power Electronics

As a Mechanical Design Engineer in Tesla's HV Devices team, you will design cutting edge High Voltage & High Current electrical safety devices for use across the entirety of Tesla, from Vehicle and Energy Storage to Solar and Manufacturing. You will be joining an elite team of driven engineers with a huge scope, reach, and potential impact.
We are hardcore. The work is fast-paced and challenging. Tesla's mission and vision must excite you.
The HV Devices team designs beyond traditional actuating devices like sealed contactors and Pyrotechnic breakers, improving integration, efficiency, safety/performance, and cost. You will be required to know and apply statics & dynamics, thermals, mechanics & vibration, and more. Our work is highly multi-disciplinary and you will be 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/grow are must-haves.
At Tesla, our design work doesn't only exist on a computer screen and we don't waste time on products that we don't see a future in. Your designs will come to life and exist in the real world within industry record time. Design engineers will scope the requirements, drive prototype builds, conduct engineering testing, and develop validation plans for our products. Your day-to-day tasks will involve design, analysis, and testing of all structural, thermal, environmental, and insulating aspects of device components and their electrical connections. An example might be the detailed design of a flexible busbar system capable of conducting high currents and actuating reliably for thousands of cycles - search for Cybertruck DPDT. You will own the design from conception thru its full evolution to mass-production.
Roles available at multiple seniority levels i.e. Sr, Staff, etc. for those with more experience.

Responsibilities

• 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 kinematic, thermal, structural, design for assembly, and design for test
• Collaborate with program stakeholders to integrate designs into vehicles, energy products, and more
• Solve packaging issues: electrical isolation, sealing, thermal management, interconnection, shock and vibration management, etc.
• Develop engineering and reliability test plans for designs, including detailed analysis of results
• Create drawing packages and manufacturing instructions for parts and assemblies
• Assist in engineering prototype builds and component fabrication
• Collaborate with other mechanical, systems, electrical, magnetic, digital control, manufacturing, industrial design, and test engineers to take designs from concept through prototype to mass production

Requirements

• 4+ years of experience in mechanical design/related field OR demonstrated technical excellence in product design & analysis
• Strong mechanical engineering fundamentals & physics first-principles
• Knowledge of GD&T, tolerance stacks, design for manufacturing/automation/test/reliability (DFM/DFA/DFT/DFR). Experience with DFMEA and PFMEA, design for autmotive functional safety
• Experience using CATIA V5 and/or V6 3DExperience a plus
• Experience with PLM systems, engineering changes, deviations, BOM structuring, etc.
• Working knowledge of MATLAB, Simulink, Python, & Ansys. Experience with modeling, finite element analysis (FEA), & multi-physics simulations
• Experience with environmental, reliability, safety, and industry standards for automotive, industrial & residential products
• Basic understanding of electrical design fundamentals
• Familiarity with PCBAs, PCBA components, battery management systems, relays, fuses, contactors, switchgear, solenoids, and/or electric motors
• Experience with high volume manufacturing and automated assembly processes such as injection molding, stamping, diecast, fastening, welding, dispensing, etc.

Compensation and Benefits
Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Aetna PPO and HSA plans > 2 medical plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Account) HSA Contribution when enrolled in the High Deductible Aetna medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D, short-term and long-term disability insurance
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program
Expected Compensation

$92,720 - $206,520/annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.