Sr. Mechanical Design Engineer, Aerodynamic Prototypes, New Program Engineering

What To Expect The Sr. Mechanical Design Engineer role within the Aerodynamic Prototype team will lead the design, build & test of physical models in coordination with the Aerodynamics Engineering team. Tesla places a strong emphasis on vehicle aerodynamic optimization, not only for efficiency & range, but for wind noise as well. Our group works closely with Design & other engineering groups to achieve maximum performance with minimal compromise to other attributes. The Aerodynamic Prototype team is small, highly motivated & thrives in a rapid engineering environment. This role offers the rare opportunity to participate in the development of new & genuinely cutting‑edge vehicles. You must have a genuine passion for engineering the best EVs in the world. What You’ll Do Lead the design & create build plans for wind tunnel models that align with the aerodynamicists’ test plans & program deliverables Execute build plans by designing, releasing & coordinating the build of test properties for wind tunnel & on‑vehicle tests Perform hand calculations & FEA to justify mechanical design decisions for models and ensure structural performance of physical asset Work with engineers, suppliers, model makers & fabricators to create, assemble, instrument & test high fidelity wind tunnel models & physical mockups Lead innovation efforts to develop & improve processes continuously Mentor & support team members and interns through brainstorming sessions and technical design reviews What You’ll Bring Degree in Mechanical Engineering or equivalent with minimum of 5 years of equivalent experience in a product development environment Demonstrated proficiency with Finite Element Analysis (FEA), ability to interpret CAE results and integrate recommendations into product designs Effectively handle multiple priorities, organize workloads, and meet tight delivery timelines. Create schedules and report to leadership how the early design decisions track to critical program level milestones Proficiency in CAD (Computer Aided Design) software using parametric elements and knowledge‑based engineering tools Detail‑oriented personality with effective documentation and reporting Excellent communicator, resourceful, and mindful of time management Must be proactive in improving processes & driving projects, examples of this should be provided Familiarity with common aerodynamic measurement systems like pressure sensing & load cell hardware Experience with track testing or wind tunnel testing, either at model or full scale preferred Must be willing to travel 10% of working days to support on‑track & tunnel testing Benefits Compensation and 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 Expected Compensation $104,120 - $222,300/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 #J-18808-Ljbffr Tesla