About the role#
As a Thermal Design Engineer intern within the Energy Engineering team, you will contribute to the development of battery, charging, and renewable technologies. You will work on thermal systems for products such as Megapack, Supercharger, and data center programs. This role involves taking ownership of components and systems from the initial concept through production launch and ramp.
What you'll do#
- Design and integrate components including fan and heat exchanger assemblies, vapor compression cycles, and coolant systems.
- Perform thermal and fluid reduced order modeling and feasibility studies to inform mechanical designs.
- Develop and execute validation plans and test methods to ensure products meet all requirements.
- Build engineering prototypes and fabricate components.
- Define specifications for dimensions, performance, and manufacturing.
- Create detailed drawing packages and manufacturing instructions.
- Collaborate with systems, electrical, supply chain, manufacturing, and reliability teams to move designs into mass production.
- Solve root causes for test failures and production issues.
- Travel to support launch, ramp, and debug activities at factories or test facilities.
What you'll need#
- Currently pursuing a degree in Mechanical Engineering or a related field.
- Strong fundamentals in heat transfer, fluids, mechanics, and electronics.
- Experience with thermal analysis and CFD.
- Proficiency in CATIA V5 or V6.
- Working knowledge of Python or Matlab.
- Ability to create products from CAD design to hands-on prototyping.
- Understanding of material science regarding metals, insulators, plastics, and gaskets.
- Knowledge of GD&T, finite element analysis, and design for reliability concepts.
- Basic understanding of electrical design fundamentals.
- A detail-oriented approach to documentation and reporting.
- Experience with student projects like Formula Vehicle, Solar Car, or Hyperloop is a plus, as are direct machine shop skills.
Location & details#
- Location: Palo Alto, California.
- Term: Winter 2027 and Summer 2027.
- Modality: Full-time, on-site.
- 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.
