Tesla Motors, Inc.
Sr. Mechanical Design Engineer, Test Infrastructure & Systems Engineering
Tesla Motors, Inc., Palo Alto, California, United States, 94306
What to Expect
Tesla Energy's Test Infrastructure team is seeking a Mechanical Design Engineer to develop automated test equipment and mechanical infrastructure for energy storage, EV charging, and solar products. The role requires expertise in 3D modeling (CATIA), sheet metal design, prototyping, electromechanical packaging, 80/20 structures, mechanical component sourcing, and build oversight. 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.
What You\'ll Do
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
What You\'ll Bring
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
Compensation and 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 $106,400 - $256,200/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.
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Tesla Energy's Test Infrastructure team is seeking a Mechanical Design Engineer to develop automated test equipment and mechanical infrastructure for energy storage, EV charging, and solar products. The role requires expertise in 3D modeling (CATIA), sheet metal design, prototyping, electromechanical packaging, 80/20 structures, mechanical component sourcing, and build oversight. 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.
What You\'ll Do
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
What You\'ll Bring
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
Compensation and 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 $106,400 - $256,200/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.
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