Sr. Mechanical Design Engineer, Test Infrastructure & Systems Engineering

Tesla Energy's Test Infrastructure team is seeking a Mechanical Design Engineer to develop automated test equipment and mechanical infrastructure for energy storage, EV charging, and solar products. The role requires expertise in 3D modeling (CATIA), sheet metal design, prototyping, electromechanical packaging, 80/20 structures, mechanical component sourcing, and build oversight.You will work closely with Electrical and Controls Engineers to integrate mechanical and electrical elements into robust test solutions. This includes bus bar fabrication, wire harness routing, bulkhead selection/mounting, enclosure design, and thermal management solutions (coolant loops, airflow, heat exchangers). The role involves both hands-on prototyping and design-for-manufacturing, as well as coordinating builds and outsourcing fabrication.

Responsibilities

• Design, develop, and maintain mechanical test infrastructure, including custom enclosures, thermal systems, electromechanical packaging, and automation rigs
• Own 3D modeling (CATIA preferred) for sheet metal, machined parts, 80/20 extrusions, and structural test setups
• Prototype and validate mechanical solutions, integrating bus bars, wire harnesses, and bulkhead penetrations for high-power electrical test systems
• Support harness routing, ensuring strain relief, serviceability, and proper mounting to align with EE design requirements
• Select and design bulkhead penetrations for high-voltage, coolant, and signal routing, ensuring compatibility with electrical and thermal constraints
• Oversee technician teams to support assembly, troubleshooting, and maintenance of mechanical test setups
• Manage outsourcing efforts, working with vendors and machine shops for custom mechanical and electrical hardware fabrication
• Optimize thermal management solutions, including coolant loops, heat exchangers, and airflow design for high-power test environments
• Work closely with cross-functional teams (EE, Controls, Firmware, etc.) to ensure seamless mechanical-electrical integration

Requirements

• Degree in Mechanical Engineering, Mechatronics Engineering, or equivalent experience
• 3+ years of experience designing mechanical systems, with expertise in test equipment, industrial automation, or electromechanical packaging
• Expert proficiency in 3D CAD (CATIA preferred) for sheet metal, enclosure design, and mechanical packaging
• Experience designing with 80/20 extrusions, sheet metal, machined parts, and off-the-shelf mechanical components
• Strong prototyping skills, including material selection and hands-on fabrication, as well as assembly, testing, and iteration
• Ability to source mechanical components, manage builds, maintain BOMs, and work with vendors and machine shops for outsourcing
• Strong ability to manage multiple projects in a fast-paced environment
• Preferred: Familiarity with high-power/high-voltage systems, and experience with bus bar fabrication, wire harness integration, and bulkhead mounting for high-power test setups
• Preferred: Understanding of thermal and fluid dynamics, including experience with coolant loops, heat exchangers, and airflow management
• Preferred: Prior experience working in R&D or fast-paced prototyping environments

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)
• 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

$106,400 - $256,200/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.

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