Mechanical Design Engineer, Injection Molding

Role details

What to Expect

Tesla’s Materials Manufacturing Engineering team is at the forefront of developing first-of-a-kind processes which allow us to produce amazing vehicles at best-in-class quality and rate; in a safe and ergonomic environment.

The Machining & Coatings team is seeking a Mechanical Design Engineer to focus on supporting the scaling of our operations and product range. This includes executing design and automation projects for integration in any one of Tesla’s global facilities. The candidate is a self-starter and strong independent worker, who can collaborate closely with internal cross-functional teams, external vendors, and technology partners to take a project from concept to full production.

The candidate will collaborate with Product Design, tool designer, simulation, and Process Engineering to establish Injection Molding tooling requirements, creating fully detailed 3D CAD tooling design models for mold fabrication by tooling suppliers.

The ideal candidate takes pride in their hands-on work, analytical ability, organizational skills and attention to detail. They appreciate an environment where superior work is encouraged, noticed and rewarded and where individuals carry tremendous responsibility. They look forward to learning an incredible amount on the job. This position requires up to 15% travel.

What You'll Do

• Own plastic injection mold and thermal simulation from initial design concept through tool release
• Optimize injection mold process parameters; fill (time, flow front, weld lines, air traps, shear) and pack/hold (switchover, gate freeze, pack profile, sink, shrinkage)
• Run the loop from gate and runner design through vents, waterlines, hot-spot closure, thermal cycling, mold deflection, and warpage
• Size cooling circuits, model melt behavior, and check the tool for deflection, thermal stress, and fatigue under clamp and injection loads
• Own simulations/analysis of adjacent forming processes; vacuum film thermoforming of viscoelastic polymers, radiant heating (IR emitter layout, zone control, view factors, radiative exchange, optical ray tracing)
• Give product design early DFM input, process-engineering feedback into new and replacement tools, and improve cycle time, yield, and uptime
• Provide supporting design validation analysis (FMEA, FEA, CFD, etc.)
• Participate in on-site construction and commissioning activities, serving as the point of contact for technical inquiries and real-time issue resolution
• Provide technical oversight of tooling suppliers and coordinate project activities and resolve project issues with customers, suppliers, and functional owners
• Provide comprehensive equipment validation documentation, ensuring all specifications met

What You'll Bring

• Degree in Mechanical Engineering, Materials Science, Polymer/Plastics Engineering, or a related field, or equivalent experience
• Minimum 3 years related experience in a technology-based industry, where automated assembly techniques are utilized (high-volume process experience preferred)
• Trial hands-on and injection molding simulation (Moldflow, SIGMASOFT, or equivalent) across fill, pack, cool, and warp analyses for injection molding
• CFD and heat transfer proficiency (STAR-CCM+, Ansys Fluent, or similar), including conjugate heat transfer; working knowledge of structural and thermo-mechanical CAE (ANSYS or similar) for mold tools
• Strong fundamentals in materials science and polymer rheology, including non-Newtonian flow and viscoelasticity
• Experience with viscoelastic flow solvers (Ansys Polyflow, or equivalent) and constitutive models for polymer melts (K-BKZ, Ogden) is a plus, for thermoforming, blow molding, and related forming processes
• Injection mold tool design using 3D CAD (CATIA preferred)
• Knowledge of materials science and understanding of the chemical properties and behavior of materials, such as PUR/PUA and other thermoplastic polymers
• Excellent organizational skills and meticulous attention to detail; mastery of MS Office suite, Confluence, Jira, Word, Excel, PowerPoint, etc.
• Ability to travel up to 15%

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans > plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D
• Short-term and long-term disability insurance (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)

Expected Compensation

$109,600 - $195,600/annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.

Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws.

Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.