Sr. Battery Mechanical Design Engineer, Megapack

Tesla Energy is bringing battery, solar, and charging technologies to the grid, establishing new industries and defining the future of renewable energy ecosystems. This team is at the forefront of how we will generate, distribute, and consume power today and in the future.

As part of the Battery Module Design Team, you will design the battery systems that help make Tesla Energy products world class, working with a highly motivated and interdisciplinary team that rethinks how battery systems should be designed from the ground up, starting from blank page designs and building up to the top-level system design ownership with a first principles design approach.

The role is collaborative and cross-functional, requiring extensive interfacing with teams including but not limited to systems engineering, parallel design teams, electrical/firmware engineering, validation test, manufacturing, service, to name a few. This role requires the ability to apply engineering fundamentals to design battery systems that are at the core of Tesla’s success. Our team is composed of individuals who are thoughtful, fast-moving, self-motivated, who love to solve difficult problems, and are team players.

• End-to-end ownership of the battery system designs for new and existing Tesla Energy products, ensuring the designed parts and system meet the optimized requirements and can successfully scale into mass production
• Component and system mechanical design ownership of entire battery systems; converting requirements into design concepts and materializing these concepts into physical, validated, mass-production-ready parts/systems
• Build-to-print mechanical design component design ownership, inclusive of current collectors, battery chassis, isolation strategies, adhesive joints, cold plates / cooling tubes, high voltage interconnects etc
• Develop and execute component and subsystem design validation plans and test methods to validate product adherence to requirements, in collaboration with parallel validation and systems engineering teams
• Collaborate with cross-functional teams to refine requirements and specifications to optimally achieve product performance, schedule, cost, reliability, and quality targets
• Develop trade studies to guide management level decisions for future product roadmap

• Minimum of 3 years of product design experience
• Proficiency in CAD modeling, CATIA V5/6 a plus
• Experience designing for high volume production
• Experience in structural analysis including structural FEA, vibration/dynamic analysis, thermal structural analysis, bolted joints, fatigue, etc, and the ability to efficiently simplify analysis
• Understanding of material science of components used in mechanical design (metals, insulators, plastics, connectors, gaskets, etc) and their fabrication processes (injection molding, thermoforming, casting, forging, bonding, brazing/welding, machining, etc.)
• Proficiency in GD&T, a thorough understanding of tolerances, and development of high-quality drawing packages/manufacturing instructions for parts and assemblies
• Familiarity with battery cell manufacturing and design, cell characteristics and cell fundamentals (swelling, DCR, PPR, etc.) is preferred