Tesla Sr. Mechanical Design Engineer Electrical Safety Devices Power Electronics 

United States, California, Palo Alto 

718902478

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.

• 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

• 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.