Mechanical Design Engineer, Optimus Gears

Description:
Tesla’s actuator team designs and builds actuators for humanoid bi-pedal robots (Tesla Bot). The team integrates mechanical, electrical, and electromagnetic engineering disciplines in a collaborative environment.
This role focuses on the design, optimization, and industrialization of high-performance gear systems for electromechanical actuators. You will contribute to gear design efforts to achieve exceptional torque density, efficiency, and reliability in rotary and linear actuator applications.

Responsibilities:
Design and optimize gear trains for torque and force density in rotary/linear actuator systems

Collaborate with electromagnetic motor teams to align gear systems with motor performance goals

Evaluate and implement advanced gear technologies (e.g., planetary, cycloidal, harmonic drives) for efficiency and reliability

Develop prototypes for validating gear system performance under dynamic loads

Conduct thermal, stress, and wear analysis to ensure gear durability and reliability

Partner with manufacturing and supply chain teams to refine gear production processes

Troubleshoot and resolve gear-related performance issues during prototyping and production

Document gear design specifications and test results for iterative improvement

Explore novel gear configurations to reduce weight, cost, and complexity

Support validation of gear systems against actuator-level efficiency and torque requirements

Requirements:
Degree in Mechanical Engineering or related field with expertise in gear design, or equivalent experience (advanced degree preferred)

3+ years designing rotary/linear gear systems for high-torque electromechanical applications

Proven experience in gear train optimization for efficiency, durability, and force density

Proficiency in CAD tools (e.g., SolidWorks, CATIA) for gear system design

Deep understanding of planetary, cycloidal, harmonic, and ball screw gear mechanisms

Experience with finite element analysis (FEA) or computational modeling for gear systems

Knowledge in common tools like, MASTA, ROMAX, Transmission 3D, etc.

Familiarity with gear manufacturing processes (e.g., hobbing, grinding, 3D printing)

Strong analytical skills in thermal management and mechanical stress analysis

Hands-on experience with gear prototyping, testing, and calibration and knowledge of industry standards (e.g., AGMA, ISO) for gear design and quality

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
$108,000 - $240,000/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.