Tesla

Makes electric cars, robotaxis and grid batteries

Mechanical Design Engineer - High Voltage Distribution, Powertrain Engineering Europe

Design EngineeringPosted on Nov 14

Full-timeBerlin, GermanyNo salary listedIn-person

About the Job

Requirements

A BS, MS, or PhD in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, Mechatronics, or a related field is required.
Deep understanding of mechanical engineering fundamentals, including heat transfer, fluids, statics, dynamics, and structural design.
Significant experience designing and building mechanical assemblies and electromechanical components.
Strong knowledge of materials used in electronics packaging, including metals, insulators, plastics, connectors, gaskets, thermal interface materials, and potting.
Proficiency with 3D mechanical design and analysis tools, including CATIA V5 and/or V6 and ANSYS.
Experience using geometric dimensioning and tolerancing (GD&T) to control part features and ensure manufacturability.
Hands-on experience building and testing prototypes.

Responsibilities

Design mechanical components across the full high-voltage stack, including battery, high-voltage distribution, and harnesses, from concept through mass production, improving performance, cost, and mass.
Create complex 3D and 2D models and assemblies, and manage large assemblies and master sections.
Perform and lead design failure mode and effects analysis (DFMEA), design for manufacturability (DFM) studies, and computer-aided engineering (CAE) simulations and hand calculations covering mechanical, thermal, and stack-up analysis to validate design concepts before physical builds.
Define validation plans and develop test jigs and fixtures to validate battery components, high-voltage harnesses, and connectors.
Own testing strategy and analysis; conduct and oversee thermal testing, characterization, and functional validation.
Respond to manufacturing, process, and quality issues to unblock production ramp constraints and support product launch.
Work with manufacturing, testing, new product introduction (NPI), and supply chain teams to support prototype builds, resolve manufacturing bottlenecks, and debug field quality issues.
Lead root cause analysis (RCA) investigations for test failures and process issues, and drive immediate and long-term product improvements.
Create and maintain authoritative documentation, including 2D drawings, specifications, and release notes.

Desired Qualifications

Basic understanding of electrical design fundamentals, preferably including mechanical component design for high-voltage products.
Experience with high-volume manufacturing processes such as injection molding, stamping, die casting, extrusion, laser welding, and harness production.
Experience with product lifecycle management (PLM) systems, engineering changes (ECO), deviations, and bill of materials (BOM) structuring.
Knowledge of environmental, reliability, and safety requirements for automotive applications.
Experience with design for manufacturing (DFM) at scale.
Proficiency in root cause analysis methods such as Fishbone, 5 Whys, and 8D.
Familiarity with automotive standards such as USCAR, LV, and ISO.
Awareness of electromagnetic interference (EMI) requirements relevant to high-voltage design.
For senior/staff levels, leadership and interdisciplinary skills; serving as the point of contact for internal and external technical or organizational topics within the team; identifying and solving day-to-day work constraints and defining long-term development plans while motivating the team; owning product and product attributes from specification through design, simulation, prototype, validation, high-volume manufacturing support, and field studies; and driving collaboration beyond engineering working teams to take designs from a clean sheet through prototypes and into mass production.

Category	Engineering & Information Technology
Location	Berlin, BE
Requisition ID	289167
Type	Full-time

Job Description

Mechanical engineers within the High Voltage Battery and High Voltage Distribution team routinely tackle extremely difficult engineering challenges and continuously push beyond what was deemed impossible regarding mechanicalpackaging, electrical and thermal performance, cost, and delivery timelines.The team owns the vehicle’s high-voltage backbone. The variety of products extends from cell packaging, interconnection, battery module and its integration in the pack, to cooling, thermals, protection, and distribution. It also encompassesHV distribution inside and outside the pack: from chargeport, and distribution to the HV battery and Drive Inverter, as well as the HV harness and its connectorization, including designing full-stack HV connectors.Our teams operate with a non-conventional automotive product development philosophy of high interdisciplinary collaboration, flat organizational structure, and technical contribution at all levels. You would be expected to challenge and tobe challenged, to create, and to innovate.Working in a fast-paced, entrepreneurial company should be a pleasure for you. We are building real products. This should excite you. You would work alongside exceptionally motivated engineers in a fast and rapidly changing environment.You are obliged to determine what makes your designs successful and excited to engineer the best electric vehicles in the world.

Job Responsibilities

Full Lifecycle Design: work on mechanical design of components across the full HV stack (battery, HV distribution, and harnesses) from concept to mass production, improving product metrics (performance, cost, mass).
Create complex 3D/2D models and assemblies. Manage large assemblies and master sections.
Engineering Analysis: Perform and lead DFMEA, DFM studies, and CAE simulations/hand calculations (mechanical, thermal, and stack-up) to validate design concepts before physical builds.
Validation Ownership: Define validation plans and develop test jigs/fixtures to validate battery components, HV harnesses, and connectors.
Testing & Characterization: Own the testing strategy and analysis. Conduct and oversee thermal testing, characterization, and functional validation.
Launch and Sustaining: Be the first responder to manufacturing/process/quality to unblock ramp limiters and drive product launch. Be comfortable wearing different hats and think out of the box.
Cross-Functional: Work closely with manufacturing, testing, NPI, and supply chain teams to support prototype builds, resolve manufacturing bottlenecks, and debug field quality issues.
Problem Solving: Lead root cause analysis (RCA) investigations for test failures and process issues; drive immediate and long-term product improvements.
Documentation: Create and maintain the "source of truth" documentation, including 2D drawings, specifications, and release notes.

Job Requirements

BS, MS, or PhD in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, Mechatronics, or a related field.
ME Fundamentals: Deep understanding of Mechanical Engineering fundamentals (heat transfer, fluids, statics, dynamics, structural design).
Design Experience: Significant experience designing and building mechanical assemblies and electromechanical components.
Material Science: Strong knowledge of materials used in electronics packaging (metals, insulators, plastics, connectors, gaskets, thermal interface materials, potting, etc.).
CAD & Analysis: Proficiency using 3D mechanical design and analysis tools (CATIA V5 and/or V6, ANSYS).
GD&T: Experience using GD&T to control part features and ensure manufacturability.
Hands-on: Hands-on experience to build and test prototypes.

Additional Preferred Skills

Basic understanding of electrical design fundamentals, preferably designing mechanical components for high voltage products.
Experience with high-volume manufacturing processes such as injection molding, stamping, die casting, extrusion, laser welding, harness production, etc.
Experience with PLM systems, engineering changes (ECO), deviations, and BOM structuring.
Knowledge of environmental, reliability, and safety requirements for automotive applications.
Design for manufacturing (DFM) at scale.
Proficiency in Root Cause Analysis methods (e.g., Fishbone, 5 Whys, 8D).
Familiarity with automotive standards (USCAR, LV, ISO, etc.).
Awareness of EMI requirements relevant to HV design.
Leadership and interdisciplinary skills (essential for Senior/Staff levels).
Be the point of contact for any internal/external technical/organizational topics within the team (essential for Senior/Staff levels).
Identify and solve restrictions in daily work, define long term development plans, and everything in between, while motivating the team through challenges (essential for Senior/Staff levels).
Start to finish ownership of product and product attributes from specification to design, simulation, prototype, validation, and support high-volume manufacturing and field studies (essential for Senior/Staff levels).
Drive collaboration beyond engineering working teams to take designs from a clean sheet through prototypes and into mass production (essential for Senior/Staff levels).

About the Company

Tesla

Makes electric cars, robotaxis and grid batteries

Tesla makes electric cars and batteries that store power for homes and utilities, and it develops self-driving software and humanoid robots. In 2023, its Model Y became the first electric vehicle to rank as the world's best-selling car. Buyers order the Model 3 sedan, Model Y SUV, or Cybertruck pickup directly from Tesla instead of through dealers, and they charge on its Supercharger fast-charging network. It also sells Megapack and Powerwall batteries, runs a robotaxi service, and charges drivers a monthly fee for self-driving software that still needs their supervision. Tesla was founded in 2003, with Elon Musk as its lead early investor and a recognized co-founder, and it is based in Austin, Texas.

Company size: 10,001+
Company stage: IPO
Headquarters: Austin, TX
Founded: 2003

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