CAE Engineer, Optimus Gears

Description:
The Tesla Robotics Team designs and builds humanoid bi-pedal robots (Optimus) to perform tasks that are boring, repetitive, and dangerous for humans. As a CAE Engineer, you will guide the structural design of gears and gear assemblies using high-fidelity FE models grounded in sound engineering principles. Working closely with mechanical, electrical, controls, software, and manufacturing teams, you’ll analyze and optimize designs, challenge traditional CAE methods, and pioneer more efficient, accurate approaches. This role places you at the forefront of critical design and engineering decisions, shaping a robust and reliable humanoid robot that has never been executed before.

Responsibilities:
Conduct Loaded Tooth Contact Analysis (LTCA) to predict contact patterns, transmission error (TE), and contact stresses under peak torque and duty-cycle loads
Define and optimize gear micro-geometry corrections (crowning, tip/root relief, twist) to compensate for system deflections and minimize gear whine and rattle
Integrate flexible housing and shaft FEA models into drivetrain simulation environments to accurately predict misalignment at the gear mesh
Move beyond component-level analysis to perform full system-level simulations, accounting for housing flexibility, shaft deflection, and thermal effects to balance durability requirements with NVH targets
Collaborate with Test Engineering to design experiments and validate simulation models against physical dyno data, tuning models based on contact pattern mark-outs and NVH measurements
Partner with Design Engineers to iterate on macro-geometry parameters (module, pressure angle, helix angle) to achieve optimal power density and provide data-driven product guidance
Establish and maintain modeling standards, methods, and best practices for current and future programs.

Requirements:
Degree in Mechanical Engineering or related field, or equivalent experience
Strong foundation in Engineering Mechanics, Computational Mechanics, Material Science, and Finite Element Theory and applications
Demonstrated ability to guide Gears and Gear Train designs through CAE, from concept to mass production, across robotics, automotive, or relevant industries
Expertise in building high-fidelity FE models at component, sub-system, and full-system levels
Proficiency in linear and non-linear static, dynamic and modal simulations and experience developing multi-physics simulation workflows (e.g., thermal-mechanical, mechanical-electrical)
Advanced knowledge in material characterization and modeling, including nonlinear elasticity, viscoelasticity, creep, and strain-rate dependent plasticity in Metals, Plastics, Polymers and Adhesives
Proficiency in CAE Tools such as BETA CAE, LS-DYNA, Abaqus, ADAMS, COMSOL, OPTISTRUCT, Design Life, FE Safe, ROMAX, MASTA, etc.
Strong programming and data analysis skills in MATLAB, Python, or equivalent
Excellent communication and interpersonal skills with the ability to collaborate effectively across cross-functional teams

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 - $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.