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Senior Thermal Design Engineer - Industrial Hardware

Company: Tesla Motors
Location: Palo Alto
Posted on: June 7, 2021

Job Description:

The Role:

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.


  • 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.)


  • 3-6 years of product design experience
  • BS or higher degree in Mechanical Engineering
  • 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
  • Excellent communication skills
  • Ability to work in a fast-paced and challenging environment

Preferred Skills:

  • Thermal system analysis expertise, FEA, and CFD experience
  • Experience designing packaging solutions for battery systems
  • Experience designing power electronic assemblies
  • Experience designing products for outdoor environments
  • Knowledge of GD&T and stackup analysis
  • Knowledge of design for reliability concepts
  • Knowledge of electrical principles and their application in renewable energy systems
  • Experience with obtaining compliance and certification to global standards
  • Experience with PLM systems, engineering changes, deviations, BOM structuring, etc.
  • Experience with environmental, reliability, safety, and industry standard requirements for industrial products
  • Familiarity with PCBAs and PCBA components

Keywords: Tesla Motors, Palo Alto , Senior Thermal Design Engineer - Industrial Hardware, Other , Palo Alto, California

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