Robotics Mechanical Design Engineer, Gears, Optimus

About the role

• Robotics Mechanical Design Engineer, Gears, Optimus | Tesla (Tesla SI)
• Location: Palo Alto, California | Req ID: 264636 | Job Type: Full-time
• What to Expect

Tesla’s actuator team designs and builds actuators for humanoid bi-pedal robots (Tesla Bot). The team integrates mechanical, electrical, and electromagnetic engineering disciplines in a collaborative environment.

This role focuses on the design, optimization, and industrialization of high-performance gear systems for electromechanical actuators. You will contribute to gear design efforts to achieve exceptional torque density, efficiency, and reliability in rotary and linear actuator applications.

What You'll Do

• Design and optimize gear trains for torque and force density in rotary/linear actuator systems
• Collaborate with electromagnetic motor teams to align gear systems with motor performance goals
• Evaluate and implement advanced gear technologies (e.g., planetary, cycloidal, harmonic drives) for efficiency and reliability
• Develop prototypes for validating gear system performance under dynamic loads
• Conduct thermal, stress, and wear analysis to ensure gear durability and reliability
• Partner with manufacturing and supply chain teams to refine gear production processes
• Troubleshoot and resolve gear-related performance issues during prototyping and production
• Document gear design specifications and test results for iterative improvement
• Explore novel gear configurations to reduce weight, cost, and complexity
• Support validation of gear systems against actuator-level efficiency and torque requirements

What You'll Bring

• Degree in Mechanical Engineering or related field with expertise in gear design, or equivalent experience (advanced degree preferred)
• 3+ years designing rotary/linear gear systems for high-torque electromechanical applications
• Proven experience in gear train optimization for efficiency, durability, and force density
• Proficiency in CAD tools (e.g., SolidWorks, CATIA) for gear system design
• Deep understanding of planetary, cycloidal, harmonic, and ball screw gear mechanisms
• Experience with finite element analysis (FEA) or computational modeling for gear systems
• Knowledge in common tools like, MASTA, ROMAX, Transmission 3D, etc.
• Familiarity with gear manufacturing processes (e.g., hobbing, grinding, 3D printing)
• Strong analytical skills in thermal management and mechanical stress analysis
• Hands-on experience with gear prototyping, testing, and calibration and knowledge of industry standards (e.g., AGMA, ISO) for gear design and quality

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.