Manufacturing Process Development Engineer

Job Description

Tesla is building Optimus, a general-purpose humanoid robot designed to perform unsafe, repetitive, and boring tasks—ultimately creating abundance through AI and robotics at a massive scale. The hand is one of the most critical and complex subsystems: a high-dexterity, tendon-driven mechanism with advanced tactile sensing. 

We are looking for a hands-on Manufacturing Process Development Engineer to drive R&D and early production process development for novel manufacturing techniques specific to the Optimus hand. This includes precision tendon (cable) routing and termination systems, advanced tactile sensor fabrication, and the integration of gloves, textiles, and soft goods for durability, protection, and human-like interaction. This is a first-principles, high-ownership role. You will develop processes that do not yet exist at scale, own them from concept through prototype and into production ramp, and directly enable the cost, quality, and throughput targets required for Optimus to ship in volume. 

Job Responsibilities

• Develop and optimize novel manufacturing processes for the tendon-driven architecture of the Optimus hand, including synthetic rope construction and termination/anchoring methods
• Lead process development for advanced tactile sensing hardware, with a focus on thermoforming, dispensing, and lamination processes
• Create and scale processes for glove, textile, and soft covering integration—including cutting, bonding, lamination, sewing, encapsulation, and assembly of soft elements onto the hand structure for sensor protection, durability, and enhanced manipulation
• Design, build, and iterate custom tooling, fixtures, molds, and process equipment to support rapid R&D builds and transition to repeatable, production-intent processes
• Execute Design of Experiments (DOE), process characterization, and capability studies. Establish robust process windows and controls for new materials and high-precision assemblies
• Partner closely with mechanical design, actuator, sensor, and controls teams to provide DFM input early, driving designs that achieve high dexterity while enabling extreme cost reduction and high-volume manufacturability
• Own process documentation (work instructions, SOPs, control plans, travelers) and support prototype builds, yield improvement, and issue resolution through pilot production
• Collaborate with supply chain and internal teams on in-house vs. supplier process strategies for specialty materials
• Conduct raw material selection and vendor qualification, establishing strict quality standards to meet cost and performance objectives
• Drive first-principles cost, cycle time, and reliability improvements to make the Optimus hand production-ready at scale

Job Requirements

• Degree in Mechanical Engineering or a related field (advanced degree or relevant certifications are a plus), or equivalent industry experience and evidence of exceptional ability
• 5+ years of hands-on manufacturing process development experience, with a track record taking complex precision or flexible assemblies from prototype through production ramp and yield improvement
• Direct experience developing processes in at least two of these areas (strong preference for all three): Tendon, cable, or flexible routing/termination systems (especially in high-cycle or high-precision mechanisms); Polymer thermoforming, vacuum/pressure forming, or thin-film forming processes with integrated electronics or sensors (TPU or similar thermoplastics experience highly relevant); Textile, soft goods, glove, or wearable assembly processes (bonding, lamination, sewing, or hybrid rigid-flex integration)
• Strong capability in tooling/fixture design, CAD (SolidWorks or equivalent), GD&T, and experimental methods (DOE, data analysis, metrology, root cause)
• Experience creating production-grade process documentation and validation approaches
• Proven ability to thrive in fast-paced, ambiguous environments with extreme ownership and a bias for action