Staff Mechanical Design Engineer, Electrical Safety Devices

Join a fast-paced team designingcutting edgeHighVoltage & HighCurrent electrical safety devices foruseacross the entirety of Tesla. From Vehicle and Energy Storage toSuperchargingand Manufacturing,the HV Devices team looksbeyondtraditional devices like sealed contactors, fuses,andpyrotechnic breakers.Oneexampleisthe Cybertruck 'DPDT' - amotor-actuatedreconfigure contactor capable of conducting highchargingcurrent, withstanding high voltages, and actuating reliably for thousands of cycles.

You will lead efforts to pushnewdevices to new levels, improving integration, efficiency,safety/performance,manufacturability,mass,and cost.Our work is highly multi-disciplinaryand,inadditionto mechanical fundamentals,youareexpectedtoknow or learn basic electrical and magnetic physics.At Tesla, design doesn't stay on a screen,and we don't waste time on productsfor which we do not see a future.If a first-principles mindsetenergizes andexcites you, this is your chance to turn abstract ideas into real-world technologiesthat millions will rely on - built and shipped in industry-record timewhilesetting new industry standards.

Roles are available at multiple seniority levels (Senior, Staff, Sr. Staff, etc.) based on experience

• Identify keyareasfor technology development in HV Safety Devices, focusing on innovative solutions that improve efficiency, elevate voltageand powercapabilities,reduce footprints, and enable high volume manufacturability- over 1 million units per year
• Apply creative, first-principles-based problem solving to generate groundbreaking solutions that address complex engineering challenges
• Conduct multi-physics simulations and optimizations to refine designs, ensuring they meet rigorous performance, thermal, structural, and environmental requirements
• Collaborate with cross-functional teams, includingelectrical hardware, firmware, thermal, and manufacturing teams to integrate designs into broader HVarchitectures
• Develop detailed engineering test plans, prototype builds, and validation strategiesto meet truncated program timelinesfrom ideation to high volume productionwith confidence
• Oversee the modeling and design of electro-mechanical components such as solenoids, motors,HV insulation, HV interruption deviceswhile solving packaging issues like thermal management, vibration and shock, footprint reduction,interconnection, and ingressprotection
• Create comprehensive drawing packages, manufacturing instructions, and assembly processes to support rapid prototyping and scalable production

• 8+ years of experience in mechanical design/related field ORdemonstratedtechnical excellence in product design&analysis, with a proven trackrecord of bringing products tohigh volumeproduction on-timeand meeting key yield & cost targets
• Exceptional creativity andsolid foundationinfirst principlesthinking, enabling you to devise novel solutions that push the boundaries ofwhat ispossible
• Outstandingorganization, written,and verbal communication skillsto collaborate effectively, leading projects with diverse stakeholders. This is a high impact role whereyouare expected to rally an organizationanditsleadersaround your ideas
• Expertise in multi-physics simulations (e.g.,structural, thermal, kinematic, electrical,magnetic systems), optimizations, navigating system-level trade-offs andinforming device design direction
• Extensive knowledge of various manufacturing techniques, including injection molding, stamping, die casting,fastening & joining, welding & bonding, dispensing, and automationto make sure designs are high volume production ready
• Strong mechanical engineering fundamentals, knowledge of GD&T,tolerance stacks,design for manufacturing/automation/test/reliability, includingDFMEA
• Proficiency with tools like CATIA V6 3DExperience, MATLAB/Simulink or Python, ANSYS or similar
• Experience with environmental, reliability, safety, and industry standardsfor automotive,industrial,orresidential products
• Familiarity with PCBAs,PCBA components,battery management systems, electrical bussing,relays, fuses, contactors, switchgear,solenoids, and/orelectricmotors

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

• Medical plans > 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 Accounts) HSA Contribution when enrolled in the High-Deductible 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 (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly 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

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.