New

Sr. Mechanical Design Engineer, Electrical Safety Devices

Tesla Motors, Inc.
92,720 - 206,520 USD
paid holidays, flex time, 401(k)
United States, California, Palo Alto
Aug 18, 2025
What to Expect As a Mechanical Design Engineer in Tesla's HV (Safety) Devices team, you will design cutting edge High Voltage & High Current electrical safety devices for use across the entirety of Tesla, from Vehicle and Energy Storage to Charging and Manufacturing.You will be joining an elite team of driven engineers with a huge scope, reach, and potential impact. The work is fast-paced and challenging. Tesla's mission and vision must excite you. The HV Devices team designs beyond traditional actuating devices like sealed contactors and Pyrotechnic breakers, improving integration, efficiency, safety/performance, and cost. To design new mechanisms, you will be required to know and apply statics, mechanics, thermals, dynamics, 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, create designs, model mechanisms, drive prototype builds, conduct engineering testing, develop reliability validation plans, and conduct root-cause analysis for our products. An example might be detailed design of a flexible busbar system capable of switching states and conducting high currents, actuating reliably for thousands of cycles - search for the Cybertruck DPDT to learn more about this example. You will own the design from conception through its full evolution to mass-production. Roles available at multiple seniority levels i.e. Sr, Staff, etc. for those with more experience. What You'll Do Modeling and design of electromechanically actuated parts and assemblies including plastics, sheet metal, castings / extrusions, springs, high voltage connectors, fasteners, seals, and others Mechanical design analysis including kinematic, structural, thermal, and design for manufacturability 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, electrical, control systems, manufacturing, industrial design, and test engineers to take designs from concept through prototype to mass production What You'll Bring 4+ years of experience in mechanical design/related field OR demonstrated technical excellence in product design & analysis Robust foundation in mechanical engineering fundamentals & physics first-principles Proficiency in 3D CAD & PLM systems, engineering changes, deviations, BOM structuring, etc. Solid grasp of GD&T, tolerance stacks, design for manufacturing/automation (DFM/DFA) Background in modeling, finite element analysis (FEA), & multi-physics simulations Familiarity with high volume manufacturing and automated assembly processes such as injection molding, stamping, castings/extrusions, fastening, welding, dispensing, etc. Understanding of basic electrical design fundamentals. Familiarity with battery management systems, relays, fuses, contactors, switchgear, solenoids, and/or electric motors a plus Experience with CATIA 3D CAD software, Ansys, Matlab, and Python a plus Exposure to environmental, reliability, safety, and industry standards for automotive, industrial, and/or residential products Experience with DFMEA and PFMEA. Design for automotive functional safety a plus Compensation and Benefits 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 $92,720 - $206,520/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.