About the role#
As a Mechanical Design Engineer within the Vehicle Power Electronics team, you will design power converters for the Tesla vehicle lineup, energy products, and AI data centers. This role involves a multi-disciplinary approach where you will apply principles of statics, dynamics, fluid mechanics, and thermal management to real-world hardware. You will own designs from the initial concept through to mass production, working alongside electrical, magnetic, and manufacturing engineers.
What you'll do#
- Model and design electro-mechanical parts and assemblies, including plastics, sheet metal, heat sinks, insulation systems, magnetic components, and high voltage connectors.
- Perform mechanical design analysis, including thermal, CFD, structural, design for assembly, and design for test.
- Solve electronics packaging challenges such as electrical isolation, sealing, thermal management, shock and vibration, EMI, and RF communications.
- Develop engineering test plans and create drawing packages and manufacturing instructions.
- Assist in engineering prototype builds and component fabrication.
- Collaborate with cross-functional teams to integrate designs into vehicles and energy products.
What you'll need#
- Currently pursuing a degree in Engineering, Power Electronics, Mechanical Engineering, or a related field.
- Experience designing packaging for electronic assemblies and an understanding of component fabrication processes.
- Knowledge of material science for mechanical design, including metals, insulators, plastics, gaskets, and thermal interface materials.
- Proficiency in 3D mechanical design and analysis tools, specifically CATIA V5/V6, ANSYS Icepak, and StarCCM.
- Experience with PLM systems, BOM structuring, and engineering change processes.
- Familiarity with GD&T, finite element analysis, and design for reliability concepts.
- Working knowledge of Matlab, Python, and ANSYS.
- Understanding of high-volume manufacturing processes like injection molding, stamping, and diecasting.
- Basic understanding of electrical design fundamentals and PCBA components.
Location & details#
- Location: Palo Alto, California.
- Terms: Winter 2027 or Summer 2027.
- Modality: On-site, full-time (40 hours per week).
- Duration: Minimum of 12 weeks.
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.
