Sr. Mechanical Design Engineer, Power Electronics

Description:
As a Mechanical Design Engineer in Tesla's Power Electronics team, you will design cutting edge, world-class power converters in use across the entirety of Tesla, from Vehicle and Energy Storage to Solar and Manufacturing.  You will be joining an elite team of driven engineers with a huge scope, reach, and potential impact.
We are hardcore. The work is fast-paced and challenging.  Tesla’s mission and vision must excite you.
Power electronics is unique.  Despite its name, it pushes the limits of the wide breadth of mechanical engineering.  You will be required to know and apply statics & dynamics, fluids & thermals, mechanics & vibration, 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 drive prototype builds, engineering testing, and validation of our products.  Your day-to-day tasks will involve design, analysis, and testing of all structural, thermal, environmental, and insulating aspects of converter components and their electrical connections.  An example would be the detailed design of custom magnetic components such inductors or transformers.  You will own the design from conception thru its full evolution to mass-production.
Roles available at multiple seniority levels i.e. Sr, Staff, etc. for those with more experience

Responsibilities:
Modeling and design of electro-mechanical parts and assemblies including plastics, sheet metal, heat sinks, insulation systems, magnetic components, high voltage connectors, fasteners, and other components

Mechanical design analysis including thermal, CFD, structural, design for assembly, and design for test

Collaborate with program stakeholders to integrate designs into vehicles, energy products, and more

Solve electronics packaging issues: electrical isolation, sealing, thermal management, interconnection, shock and vibration management, electromagnetic interference (EMI), RF communications, etc.

Develop engineering test plans for designs

Create drawing packages and manufacturing instructions for parts and assemblies

Assist in engineering prototype builds and component fabrication

Collaborate with other mechanical, systems, electrical, magnetic, digital control, manufacturing, industrial design, and test engineers to take designs from concept through prototype to mass production

Requirements:
4+ years of full-time industry experience in mechanical design-related field or demonstrated technical excellence in product design and analysis

Strong mechanical engineering fundamentals & physics first-principles

Strong organization, written, and verbal communication skills

Knowledge of GD&T, tolerance stacks, design for manufacturing/automation/test/reliability (DFM/DFA/DFT/DFR).  Experience with DFMEA and PFMEA

Experience using CATIA V5 and/or V6 3DExperience

Experience with PLM systems, engineering changes, deviations, BOM structuring, etc.

Working knowledge of MATLAB, Simulink, Python, Ansys, & StarCCM.  Experience with modeling, finite element analysis (FEA), computational fluid dynamics (CFD), & multi-physics simulations

Experience with environmental, reliability, safety, and industry standards for automotive, industrial & residential products

Basic understanding of electrical design fundamentals. Familiarity with PCBAs and PCBA components

Experience with high volume manufacturing and automated assembly processes such as injection molding, stamping, diecast, fastening, dispensing, joining, etc.

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
$109,600 - $195,600/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.