Tesla

Makes electric cars, robotaxis and grid batteries

Materials Design and Reliability Engineer - Energy Products

Mechanical EngineeringPosted on Nov 6

Full-timePalo Alto, CA, USANo salary listedIn-person

About the Job

Requirements

A degree in Polymer Science, Materials Science, Mechanical Engineering, Electrical Engineering, or a related discipline, or equivalent practical experience.
At least 5 years of experience performing and leading mechanical, thermal, and reliability assessment of polymeric materials for energy storage and conversion devices such as transformers, bushings, sensors, capacitors, cables, or power modules.
Strong understanding of polymer structure–property relationships, dissimilar-material interfacial failures, insulation degradation mechanisms, and thermo-mechanical degradation.
Hands-on experience with one or more polymer processing methods, including mixing, compounding, potting, casting, molding, coating, encapsulation, and impregnation.
Hands-on experience in material characterization, reliability testing, and failure analysis for elastomers, coatings, adhesives, and composites, including viscosity, rheology, hardness, physical and mechanical properties such as glass transition temperature, compressive strength, tensile strength, elongation, and adhesion strength, coefficient of thermal expansion, thermal conductivity, and related analytical techniques.
Experience translating material behavior and failure mechanisms into practical design rules, validation plans, and process controls.
Experience working cross-functionally to solve technical problems across design, manufacturing, reliability, and supply chain.
Ability to work independently and collaboratively in a project-focused environment.

Responsibilities

Own material design for reliability, including failure analysis, testing, proposing and implementing mitigation actions, and identifying and qualifying materials to meet electrical, thermal, mechanical, and production requirements.
Work across dielectric materials, adhesives, potting, encapsulation, coatings, and composite insulation systems, using first principles to make engineering trade-offs among reliability, manufacturability, and cost.
Integrate material degradation, long-term reliability, and manufacturing process considerations as one engineering problem.
Lead DFMEA and PFMEA activities by identifying material-related design and process risks and driving mitigation plans.
Define and execute accelerated test methods; lead technical investigations of materials and components under aging to identify failure modes and mechanisms, including partial discharge, dielectric breakdown, delamination, hydrolysis, environmental stress cracking, and other thermo-mechanical degradation.
Characterize and evaluate adhesion, surface delamination, dielectric strength, partial discharge behavior, dielectric loss, thermal and mechanical properties, environmental robustness, and long-term reliability.
Translate application-level functional requirements into critical material properties and structure–property relationships.
Drive mitigation actions and material and process selection decisions that improve product reliability and manufacturability.
Partner with Mechanical Engineering, Electrical Engineering, Manufacturing, Quality, and Supply Chain to develop and optimize reliable prototyping and manufacturing processes for dispensing, potting, molding, encapsulation, coating, and assembly.
Help establish and review internal standards and validation methods for materials and component reliability assessments.

Desired Qualifications

Experience with thermo-mechanical analysis or modeling of insulation systems under thermal cycling and other reliability testing.

Category	Energy Engineering
Location	Palo Alto, California
Requisition ID	289138
Type	Full-time

Job Description

<p>Tesla is seeking a Materials Design and Reliability Engineer to support our Energy product line. You will own material design for reliability, including failure analysis, testing, proposing and implementing mitigation actions, to identify and qualify materials so our designs meet electrical, thermal, mechanical, and production requirements at the same time. </p><p>This role spans dielectric materials, adhesives, potting, encapsulation, coatings, and composite insulation systems. You will work across materials, processes, interfaces, and part geometries, using first principles to drive engineering trade-offs among reliability, manufacturability, and cost. You will integrate material degradation, long-term reliability, and manufacturing process as one engineering problem and solve it. </p>

Job Responsibilities

Lead DFMEA and PFMEA activities by identifying material-related design and process risks and driving mitigation plans

Define and execute accelerated test methods; lead technical investigations of materials and components under aging to identify failure modes and mechanisms, including partial discharge, dielectric breakdown, delamination, hydrolysis, environmental stress cracking (ESC), and other thermo-mechanical degradation

Characterize and evaluate adhesion, surface delamination, dielectric strength, partial discharge behavior, dielectric loss, thermal and mechanical properties, environmental robustness, and long-term reliability

Translate application-level functional requirements into critical material properties and structure–property relationships

Drive mitigation actions and material and process selection decisions that improve product reliability and manufacturability

Partner with Mechanical Engineering, Electrical Engineering, Manufacturing, Quality, and Supply Chain to develop and optimize reliable prototyping and manufacturing processes for dispensing, potting, molding, encapsulation, coating, and assembly

Help establish and review internal standards and validation methods for materials and component reliability assessments

Job Requirements

Degree in Polymer Science, Materials Science, Mechanical Engineering, Electrical Engineering, or a related discipline, or equivalent practical experience
5+ years of experience performing and leading mechanical, thermal, and reliability assessment of polymeric materials for energy storage and conversion devices, such as transformers, bushings, sensors, capacitors, cables, or power modules

Strong understanding of polymer structure–property relationships, dissimilar-material interfacial failures, insulation degradation mechanisms, and thermo-mechanical degradation; experience with thermo-mechanical analysis or modeling of insulation systems under thermal cycling and other reliability testing is a plus

Hands-on experience with one or more polymer processing methods: mixing, compounding, potting, casting, molding, coating, encapsulation, and impregnation

Hands-on experience in material characterization, reliability testing, and failure analysis for elastomers, coatings, adhesives, and composites, including viscosity, rheology, hardness, physical and mechanical properties (glass transition temperature, compressive strength, tensile strength, elongation, adhesion strength etc.), coefficient of thermal expansion (CTE), thermal conductivity, and related analytical techniques

Experience translating material behavior and failure mechanisms into practical design rules, validation plans, and process controls

Experience working cross-functionally to solve technical problems across design, manufacturing, reliability, and supply chain

Detail-oriented, able to work independently and in a collaborative, project-focused environment; dependable, with excellent communication skills

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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