Power Module Mechanical Design Engineer

About the role

Power Module Mechanical Design Engineer | Tesla (Engineering & Information Technology)

Location: Palo Alto, California | Req ID: 280524 | Job Type: Full-time

What to Expect

Join the electric revolution as a Mechanical Design Engineer. You'll lead module packaging design end-to-end, from first-principles concept to high-volume production, shaping the technology that powers every vehicle and energy product we ship. Working at the intersection of thermal, mechanical, and electrical engineering, you'll partner with cross-functional teams to push the limits of efficiency, reliability, and scale. Your designs won't just hit a spec sheet, they'll drive the future of sustainable energy, and we're looking for a bold, motivated engineer ready to lead the way.

What You'll Do

• Own mechanical design and optimization of power modules, balancing thermal, mechanical, electrical, and manufacturing constraints
• Develop packaging solutions with cross-functional teams from requirements through design, validation, and production builds
• Research and introduce new packaging materials and processes (substrates, attaches, encapsulants, interconnects, and beyond)
• Create, release, and control package drawings and design documentation
• Lead or contribute to DFMEA/PFMEA and resolve packaging and assembly issues through root-cause analysis
• Support mechanical tooling design for assembly equipment as designs move into production
• Take modules from prototype through high-volume manufacturing, applying direct experience with SiC or GaN power modules and automotive power electronics / traction inverter packaging where relevant

What You'll Bring

• Bachelor’s Degree in Mechanical Engineering or equivalent experience
• Master's Degree or Doctorate Degree preferred for candidates with deep packaging or multi-physics backgrounds
• 3+ years of industry experience in power module, power electronics packaging, or closely related semiconductor packaging design
• First-principles mindset across thermal, mechanical, materials, and electrical interactions
• Strong CAD skills (SolidWorks, CATIA, or similar) and experience with FEA / multi-physics simulation (ANSYS Mechanical, ICEPAK, Q3D, or equivalent)
• Working knowledge of DFM, DFT, design for reliability, tolerance analysis, and DFMEA/PFMEA
• Familiarity with automotive reliability, environmental, and safety standards
• Hands-on knowledge of electronics packaging materials and processes: ceramics/substrates, solder or sinter attaches, encapsulation, wire bonding, adhesives, copper clip, etc.

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans > 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 Accounts) HSA Contribution when enrolled in the High-Deductible 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 (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly 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
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)

Expected Compensation$91,600 - $316,800/annual salary + cash and stock awards + benefitsPay 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.