Tesla Sr. Mechanical Design Engineer Test Infrastructure Systems Engineering 

United States, California, Palo Alto 

902832610

You will work closely with Electrical and Controls Engineers to integrate mechanical and electrical elements into robust test solutions. This includes bus bar fabrication, wire harness routing, bulkhead selection/mounting, enclosure design, and thermal management solutions (coolant loops, airflow, heat exchangers). The role involves both hands-on prototyping and design-for-manufacturing, as well as coordinating builds and outsourcing fabrication.

• Design, develop, and maintain mechanical test infrastructure, including custom enclosures, thermal systems, electromechanical packaging, and automation rigs
• Own 3D modeling (CATIA preferred) for sheet metal, machined parts, 80/20 extrusions, and structural test setups
• Prototype and validate mechanical solutions, integrating bus bars, wire harnesses, and bulkhead penetrations for high-power electrical test systems
• Support harness routing, ensuring strain relief, serviceability, and proper mounting to align with EE design requirements
• Select and design bulkhead penetrations for high-voltage, coolant, and signal routing, ensuring compatibility with electrical and thermal constraints
• Oversee technician teams to support assembly, troubleshooting, and maintenance of mechanical test setups
• Manage outsourcing efforts, working with vendors and machine shops for custom mechanical and electrical hardware fabrication
• Optimize thermal management solutions, including coolant loops, heat exchangers, and airflow design for high-power test environments
• Work closely with cross-functional teams (EE, Controls, Firmware, etc.) to ensure seamless mechanical-electrical integration

• Degree in Mechanical Engineering, Mechatronics Engineering, or equivalent experience
• 3+ years of experience designing mechanical systems, with expertise in test equipment, industrial automation, or electromechanical packaging
• Expert proficiency in 3D CAD (CATIA preferred) for sheet metal, enclosure design, and mechanical packaging
• Experience designing with 80/20 extrusions, sheet metal, machined parts, and off-the-shelf mechanical components
• Strong prototyping skills, including material selection and hands-on fabrication, as well as assembly, testing, and iteration
• Ability to source mechanical components, manage builds, maintain BOMs, and work with vendors and machine shops for outsourcing
• Strong ability to manage multiple projects in a fast-paced environment
• Preferred: Familiarity with high-power/high-voltage systems, and experience with bus bar fabrication, wire harness integration, and bulkhead mounting for high-power test setups
• Preferred: Understanding of thermal and fluid dynamics, including experience with coolant loops, heat exchangers, and airflow management
• Preferred: Prior experience working in R&D or fast-paced prototyping environments