(Associate/Senior) Mechanical Design Engineer, High Voltage Distribution, Powertrain Engineering Europe, Berlin Tesla Engineering Center (m/w/d)

What to Expect

Mechanical engineers within the High Voltage Battery and High Voltage Distribution team routinely tackle extremely difficult engineering challenges and continuously push beyond what was deemed impossible regarding mechanicalpackaging, electrical and thermal performance, cost, and delivery timelines.

The team owns the vehicle’s high-voltage backbone. The variety of products extends from cell packaging, interconnection, battery module and its integration in the pack, to cooling, thermals, protection, and distribution. It also encompassesHV distribution inside and outside the pack: from chargeport, and distribution to the HV battery and Drive Inverter, as well as the HV harness and its connectorization, including designing full-stack HV connectors.

Our teams operate with a non-conventional automotive product development philosophy of high interdisciplinary collaboration, flat organizational structure, and technical contribution at all levels. You would be expected to challenge and tobe challenged, to create, and to innovate.

Working in a fast-paced, entrepreneurial company should be a pleasure for you. We are building real products. This should excite you. You would work alongside exceptionally motivated engineers in a fast and rapidly changing environment.You are obliged to determine what makes your designs successful and excited to engineer the best electric vehicles in the world.

What You'll Do

- Full Lifecycle Design: work on mechanical design of components across the full HV stack (battery, HV distribution, and harnesses) from concept to mass production, improving product metrics (performance, cost, mass).

• Create complex 3D/2D models and assemblies. Manage large assemblies and master sections.
• Engineering Analysis: Perform and lead DFMEA, DFM studies, and CAE simulations/hand calculations (mechanical, thermal, and stack-up) to validate design concepts before physical builds.
• Validation Ownership: Define validation plans and develop test jigs/fixtures to validate battery components, HV harnesses, and connectors.
• Testing & Characterization: Own the testing strategy and analysis. Conduct and oversee thermal testing, characterization, and functional validation.
• Launch and Sustaining: Be the first responder to manufacturing/process/quality to unblock ramp limiters and drive product launch. Be comfortable wearing different hats and think out of the box.
• Cross-Functional: Work closely with manufacturing, testing, NPI, and supply chain teams to support prototype builds, resolve manufacturing bottlenecks, and debug field quality issues.
• Problem Solving: Lead root cause analysis (RCA) investigations for test failures and process issues; drive immediate and long-term product improvements.
• Documentation: Create and maintain the "source of truth" documentation, including 2D drawings, specifications, and release notes.

What You'll Bring

- BS, MS, or PhD in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, Mechatronics, or a related field.

• ME Fundamentals: Deep understanding of Mechanical Engineering fundamentals (heat transfer, fluids, statics, dynamics, structural design).
• Design Experience: Significant experience designing and building mechanical assemblies and electromechanical components.
• Material Science: Strong knowledge of materials used in electronics packaging (metals, insulators, plastics, connectors, gaskets, thermal interface materials, potting, etc.).
• CAD & Analysis: Proficiency using 3D mechanical design and analysis tools (CATIA V5 and/or V6, ANSYS).
• GD&T: Experience using GD&T to control part features and ensure manufacturability.
• Hands-on: Hands-on experience to build and test prototypes.

Additional Preferred Skills

• Basic understanding of electrical design fundamentals, preferably designing mechanical components for high voltage products.
• Experience with high-volume manufacturing processes such as injection molding, stamping, die casting, extrusion, laser welding, harness production, etc.
• Experience with PLM systems, engineering changes (ECO), deviations, and BOM structuring.
• Knowledge of environmental, reliability, and safety requirements for automotive applications.
• Design for manufacturing (DFM) at scale.
• Proficiency in Root Cause Analysis methods (e.g., Fishbone, 5 Whys, 8D).
• Familiarity with automotive standards (USCAR, LV, ISO, etc.).
• Awareness of EMI requirements relevant to HV design.
• Leadership and interdisciplinary skills (essential for Senior/Staff levels).
• Be the point of contact for any internal/external technical/organizational topics within the team (essential for Senior/Staff levels).
• Identify and solve restrictions in daily work, define long term development plans, and everything in between, while motivating the team through challenges (essential for Senior/Staff levels).
• Start to finish ownership of product and product attributes from specification to design, simulation, prototype, validation, and support high-volume manufacturing and field studies (essential for Senior/Staff levels).

Drive collaboration beyond engineering working teams to take designs from a clean sheet through prototypes and into mass production (essential for Senior/Staff levels).

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Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.