Robotics Powertrain Thermal Design Engineer, Thermal Engineering, Optimus

About the role

Robotics Powertrain Thermal Design Engineer, Thermal Engineering, Optimus | Tesla (Tesla SI)

Location: Palo Alto, California | Req ID: 278614 | Job Type: Full-time

What to Expect

We are building a general-purpose humanoid robot from the ground up, and thermal performance is a hard constraint — not an afterthought. As a Robotics Thermal Design Engineer, you will own the thermal design and analysis of joint actuator and controller subsystems, from early concept through hardware validation and into production. You will work at the intersection of mechanical, electrical, and controls engineering, ensuring that actuators operate reliably across all mission profiles and duty cycles in a highly constrained form factor.

What You'll Do

• Own the end-to-end thermal design and analysis for joint actuator and embedded controller assemblies, from concept through production
• Develop and maintain steady-state and transient thermal models (CFD/FEA) and correlate them with data from physical hardware tests
• Define thermal requirements, margins, and derating curves in collaboration with mechanical, power electronics, and firmware teams
• Conduct hands-on thermal characterization of hardware using thermocouple instrumentation, IR thermography, and calorimetry
• Select and qualify thermal interface materials, potting compounds, and adhesives for demanding mechanical and environmental conditions
• Identify and communicate thermal risks early in the design cycle, driving mitigations across current and future platforms
• Support design reviews, DVT/PVT builds, and failure analysis for thermal-related issues

What You'll Bring

• Degree in Mechanical Engineering or a related field, or equivalent experience
• Strong fundamentals in heat transfer — conduction, convection, and radiation — applied to real hardware in constrained form factors
• Proficiency in CFD/FEA thermal simulation tools (Ansys Icepak, Fluent, COMSOL, or equivalent) and a track record of correlating results to physical test data
• Experience with thermal management of power electronics — PCB-level heat spreading, TIM selection, heatsink and housing interface design, junction temperature estimation
• Comfortable working in a fast-paced, hardware-iterative environment where designs evolve quickly and ambiguity is the norm
• Strong cross-functional communication skills — you'll regularly work across mechanical, electrical, firmware, and manufacturing teams
• Advanced degrees 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.