Sr. Thermal Design Engineer, Megapack

The Tesla Energy Products team is bringing battery and solar technology to the grid to facilitate a renewable energy ecosystem and redefine the way the world will use energy in the future. As part of the Mechanical Design Team, you will design and package the thermal systems that make Tesla Energy products world class. The role requires collaboration with the thermal architecture team, enclosure engineering, manufacturing, and service, and requires the ability to apply engineering fundamentals to design thermal assemblies that are at the core of Tesla's success. Our team is composed of individuals who are fast-moving, self-motivated, resilient, who love to solve difficult problems, and are team players. If this sounds like you, then our team could the right place for you.


Responsibilities

• Design packaging and components that provide airflow management, coolant and refrigerant flow management, and thermal actuator mounting, optimizing for efficiency, cost, manufacturability, and serviceability
• Mechanical design of components and assemblies including plastics, sheet metal, structural metals, insulation systems, sealing methods, fluid connectors, fasteners, busbars, and other components, with hands on prototyping
• Develop and execute component and subsystem design validation plans and test methods to validate product adherence to requirements
• Create high quality drawing packages and manufacturing instructions for parts and assemblies
• Collaborate with thermal, systems, electrical, supply chain, manufacturing, service/deployment teams, and reliability teams to take designs from prototype through mass production
• Assist in engineering prototype builds and component fabrication
• Root cause and solve test failures and production problems
• Travel to support production launch and ramp (supplier visits, on-site at Tesla factories, etc.)

Requirements

• Bachelor's Degree in Mechanical Engineering or equivalent experience
• 3+ years of product design experience
• Experience in designing for high volume assembly, both manual and automated
• Strong engineering fundamentals in heat transfer, mechanics, and fluids
• Deep understanding of material science of components used in mechanical design (metals, insulators, plastics, connectors, gaskets, etc) and their fabrication processes
• Experience with various manufacturing processes such as plastic injection molding, welding / brazing, metal stamping, extruding, thermoforming, plating, heat treating, and bonding
• Experience defining test plans, designing test setups, and analyzing data
• A detail-oriented personality with solid documentation and reporting skills
• Proficiency in CAD modeling, CATIA preferred

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)
• LGBTQ+ care concierge services
• 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

$80,000 - $300,000/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.