About the role#
This internship focuses on the mechanical design of high-power energy converters, including hardware for Superchargers and Megapacks. You will own parts of the mechanical stack from the semiconductor package to the converter tray. This involves balancing performance and cost while designing for automated high-volume manufacturing. You will work directly with mechanical, electrical, magnetic, thermal, and manufacturing engineers to optimize hardware.
What you'll do#
- Create CAD models for mechanical components like plastics, sheet metal, heatsinks, insulation, connectors, and fasteners.
- Generate 2D drawing packages using GD&T and write manufacturing instructions.
- Perform mechanical analysis and simulation, specifically thermal CFD and structural FEA.
- Solve packaging challenges related to high-voltage insulation and heat extraction.
- Develop and execute engineering test plans.
- Build prototypes, test fixtures, and fabricate components.
- Identify root causes for test failures and hardware issues.
- Use AI tools to automate design tasks.
What you'll need#
- Current pursuit of a degree in Mechanical Engineering, Mechatronics, Materials Science, Physics, or a related field.
- Strong fundamentals in mechanical engineering and physics-based problem solving.
- Experience with CAD software, specifically CATIA V6.
- Knowledge of GD&T, DFM, and technical drafting.
- Proficiency in mechanical analysis tools including ANSYS, StarCCM, MATLAB, Python, and Cursor.
- Experience designing packaging for electronic assemblies.
- Understanding of material science, including metals, insulators, plastics, and thermal interface materials.
- Practical skills in building and prototyping.
- Experience using AI for task automation and plugin authoring.
- Strong written and verbal communication skills.
Location & details#
- Location: Palo Alto, California.
- Term: Winter 2027 and Summer 2027.
- Schedule: Full-time (40 hours per week) on-site.
- Compensation: $20.00 - $50.00 per hour plus benefits.
About Tesla
Tesla produces electric vehicles, battery storage systems, and solar energy products. Founded in 2003, the company operates six vertically integrated factories across three continents. It is headquartered in Austin, Texas, and employs over 10,000 people. The organization designs, manufactures, sells, and services its products internally.
How to get in at Tesla
Applying early at Tesla provides a distinct advantage because recruiters review candidates before the applicant pool becomes unmanageable. Intern Insider sends an instant alert the moment a role matching your target is published anywhere, so you apply among the first and get seen before the pile grows. Reaching out to the right people often yields better results than submitting to a general queue. Intern Insider surfaces the recruiters behind the company roles so you can contact them directly to ask about the position or a referral, which materially improves your response rates.
