Sr. Mechanical Design Engineer, Automated Test Equipment

We are looking for a highly motivated and hands-on Sr. Mechanical Engineer to join the Manufacturing Test Engineering team - part of the "machine that builds the machine." This team designs and builds robust, data-driven test systems for Tesla's power electronics used in vehicles, energy storage, charging solutions, and humanoid robots. The ideal candidate is detail-oriented, organized, and thrives in a fast-paced, high-responsibility environment. They take pride in hands-on problem solving, have strong analytical skills, and are eager to learn and share knowledge. This role requires flexibility and a willingness to travel both domestically and internationally to support equipment development, deployment, and collaboration with global teams. This position plays a key role in shaping the quality and performance of Tesla's core technologies and is based in Toronto, Reno, or Palo Alto.

Responsibilities
 

• Machine design of automated test equipment, which includes preparing detailed-level CAD models, pneumatic diagrams, and verifying designs using structural and thermal FEA, CFD, tolerance stack-up
• Create detailed drawings and coordinate with vendors to fabricate custom machined parts, weldments, and sheet metal components
• Selection and integration of commercial components, sensors, servos, pneumatic actuators, etc.
• Lead conceptual equipment development and carefully balance product specifications, process requirements, layout complexity, cost, and lead-time limits
• Review, identify, and provide feedback on performance, design simplicity, robustness, assembly, and installation
• Support building, debugging, validation and equipment duplication efforts, and fine-tune equipment for release to production
• Perform on-site and off-site acceptance testing (SAT/FAT) of test equipment

Requirements
 

• Degree in Mechanical Engineering, Robotics, Mechatronics Engineering, or equivalent experience
• 5+ years of experience as Mechanical/Mechatronics/Automation Engineer with focus in automation, machine design, robotics, or product development
• Versed in SolidWorks, PDM, and Ansys, or similar CAD/CAE software
• Strong understanding of drafting standards and the application of GD&T (e.g., ASME Y14.5)
• Knowledgeable in solid mechanics, pneumatics, hydraulics, dynamics, material selection, prototyping, testing methods, everyday machining, and fabrication processes
• Exposure to a wide variety of test systems, production machinery, industrial sensors, actuators, and equipment (pogo-pins, pressure transducers, temperature controllers, current meters, etc.)