Robotics Fan & Active Cooling Systems Engineer, Thermal Engineering, Optimus

About the role

Robotics Fan & Active Cooling Systems Engineer, Thermal Engineering, Optimus | Tesla (Tesla SI)

Location: Palo Alto, California | Req ID: 278616 | Job Type: Full-time

What to Expect

We are developing cooling solutions for a general-purpose humanoid robot operating under continuous dynamic loads in unstructured environments. As a Robotics Thermal Design Engineer, you will own the full design and development lifecycle of in-house fan systems — from aerodynamic concepts through prototyping, validation, and production.

You will work directly alongside an in-house motor design team to co-develop fan-motor assemblies that meet the robot's specific cooling requirements, spatial constraints, acoustic targets, and power budgets. This is a deeply hands-on role that sits at the intersection of turbomachinery, thermal-fluid systems, and electromechanical integration.

What You'll Do

• Own the end-to-end design of in-house fan systems, including blade geometry, housing, and ducting, to optimize performance, weight, and acoustics
• Translate system-level cooling targets into fan design specifications, working directly with the motor design team to create integrated fan-motor assemblies
• Define the overall airflow architecture and active cooling system layout for current and next-generation platforms
• Build and maintain CFD models to predict fan and system airflow performance and own the correlation of those models with physical test data
• Establish test protocols and acceptance criteria for fan performance, including flow bench testing, acoustic characterization, and in-system thermal validation
• Collaborate with mechanical, firmware, and controls teams on housing design, vibration management (NVH), and fan speed control strategies
• Lead DFM reviews and supplier discussions to ensure designs are reliable and producible at volume

What You'll Bring

• Degree in Mechanical Engineering or a related field, or equivalent experience
• 4+ years of experience in fan or blower design, turbomachinery, or fluid system engineering — with hardware you have taken from concept to a working, validated product
• Strong fundamentals in fluid mechanics and aerodynamics — blade design, pressure-flow characteristics, system resistance curves, and fan-system matching
• Proficiency in CFD tools (Fluent, StarCCM+, or equivalent) for internal and external airflow, with experience correlating simulation results to physical test data
• Hands-on experience with fan or pump performance testing — flow benches, pressure measurements, acoustic rigs, or equivalent test setups
• Comfortable working in constrained form factors where airflow, weight, acoustics, and space requirements all compete simultaneously
• Strong cross-functional communication — you'll regularly align with motor design, firmware, mechanical, and manufacturing teams
• Master’s degree preferred

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$108,000 - $312,000/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.