Sr. Mechanical Design Engineer, Power Electronics, Semi

As a Mechanical Design Engineer in Tesla's Semi-Truck Power Electronics Team, you will design novel, world-class products and solutions to power all systems on the truck.  Your contributions will bridge the gap between difficult engineering problems and a groundbreaking driver experience.  These trucks are beasts, easy to drive, and comfortable.  Drivers will rave about them. 

Tesla changed the passenger vehicle industry, became its new standard of excellence, and pushed the rest of its peers to follow its lead.  Tesla plans to lead a similar revolution in the trucking industry next and you will be joining an elite team of engineers focused on this goal. 

Power Electronics is unique.  Despite its name, it pushes the limits of the wide breadth of mechanical engineering.  You will be required to know and apply statics & dynamics, fluids & 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. 

We are hardcore. The work is fast-paced and challenging.  Tesla’s mission and vision must excite you. 

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 drive prototype builds, engineering testing, and validation of our products.  Your day-to-day tasks will involve design, analysis, and testing of all structural, thermal, environmental, and insulating aspects of converter components and their electrical connections.  An example would be the detailed design of custom magnetic components such inductors or transformers.  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 thermal, CFD, structural, design for assembly, and design for test

• Collaborate with program stakeholders to integrate designs into vehicles, energy products, and more

• Solve electronics packaging issues: 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, 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

• Strong organization, written, and verbal communication skills

• Knowledge of GD&T, tolerance stacks, design for manufacturing/automation/test/reliability (DFM/DFA/DFT/ DFR).  Experience with DFMEA and PFMEA

• Experience using CATIA V5 and/or V6 3DExperience

• Experience with PLM systems, engineering changes, deviations, BOM structuring, etc.

• Working knowledge of MATLAB, Simulink, Python, Ansys, & StarCCM.  Experience with modeling, finite element analysis (FEA), computational fluid dynamics (CFD), & 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 and PCBA components 

• Experience with high volume manufacturing and automated assembly processes such as injection molding, stamping, diecast, fastening, dispensing, joining, etc.