Staff Simulation Engineer

Description:
Tesla is seeking a highly skilled and analytical Battery Cell Simulation Engineer to join our Battery Cell – Supplier Industrialization Engineering team. The ideal candidate will specialize in developing and applying multi-physics simulation models that bridge the gap between battery cell manufacturing processes and the resulting electrochemical, mechanical, and thermal failure modes. This role is critical in enabling predictive quality assurance, process optimization, and failure mitigation in next-generation battery cells. You will work at the intersection of materials science, manufacturing engineering, and computational modeling to identify process-induced defects (e.g., electrode misalignment, winding/stacking process variation, particle agglomeration, electrolyte distribution anomalies) and simulate their impact on cell performance, longevity, and safety.

Responsibilities:
Develop and validate finite elements (FE), computational fluid dynamics (CFD), and electrochemical-thermal (EC-TH) simulation models to predict how manufacturing parameters (e.g., coating thickness, drying temperature, calendaring pressure, winding tension) influence internal cell architecture and degradation mechanisms

Establish digital twins of battery cell manufacturing processes (e.g., slurry mixing, coating, drying, calendaring, winding, stacking, electrolyte filling) to simulate process variability and its downstream effects on cell reliability

Correlate simulation results with experimental data from lab-scale and pilot-line production (e.g., X-ray CT, SEM, EIS, cycle testing, abuse testing) to refine models and improve predictive accuracy

Identify and model root causes of common failure modes such as lithium plating, internal short circuits, mechanical stress cracking, electrolyte dry-out, and capacity fade—tracing them back to specific process steps

Collaborate with process engineers, materials scientists, and test teams to translate simulation insights into actionable process improvements and quality control criteria

Lead the development of simulation-based design of experiments (DoE) frameworks to optimize manufacturing parameters while minimizing failure risk

Requirements:
Master’s or PhD in Mechanical Engineering, Materials Science, Chemical Engineering, Physics, or a related field, or equivalent experience

8+ years of experience in battery cell simulation or manufacturing process modeling (preferably in lithium-ion batteries)

Proficiency in simulation tools such as ANSYS, COMSOL Multiphysics, Abaqus, FEniCS, or OpenFOAM

Strong understanding of electrochemical reaction kinetics, solid-state diffusion, and thermal-mechanical behavior in battery cells

Experience with Multiphysics coupling (thermal-electrochemical-mechanical) modeling

Familiarity with battery cell manufacturing processes (coating, drying, calendaring, winding, sealing, electrolyte injection)

Strong programming skills in Python, MATLAB, or C++ for automation, post-processing, and model calibration

Demonstrated ability to interpret experimental data and use it to validate and refine simulation models

Compensation & Benefits:
Benefits

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

Expected Compensation
$152,000 - $264,000/annual salary + cash and stock awards + benefitsPay 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.