Mechanical Design Engineer, Injection Molding

The ideal 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 to full production. The 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.

• 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)
• Partner with Product Design, Tool Designers, and Process Engineering to establish tooling requirements, using simulation data to provide early DFM input, process feedback, and optimization strategies that improve cycle time, yield, and uptime
• Provide comprehensive supporting design validation analysis, including detailed FEA, CFD, and FMEA reports to drive engineering decisions
• Participate in on-site construction and commissioning activities, serving as the point of contact for technical inquiries and real-time issue resolution
• Participate in on-site commissioning activities to correlate simulation models with real-world production, serving as the technical point of contact for tooling suppliers and resolving complex project issues
• Provide comprehensive equipment validation documentation, ensuring all specifications met

• Degree in Mechanical Engineering, Materials Science, Polymer/Plastics Engineering, or equivalent experience
• 3+ years related experience in a technology-based industry, where automated assembly techniques are utilized (high-volume process experience preferred)
• Hands-on trial experience paired with injection molding simulation mastery (Moldflow, SIGMASOFT, or equivalent) across fill, pack, cool, and warp analyses
• CFD and heat transfer proficiency (STAR-CCM+, Ansys Fluent, or similar), including conjugate heat transfer, and 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) for thermoforming, blow molding, and related processes is a plus
• Mechanical design experience and 3D CAD skills (CATIA preferred) with a strong preference for injection mold tool design or related tooling development
• Excellent organizational skills, meticulous attention to detail, and mastery of collaboration tools including MS Office suite, Confluence, and Jira
• Preferred experience with vacuum film thermoforming, IR/radiative heat transfer modelling, and Python or macro scripting for simulation automation
• Ability to travel up to 15%
  

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)

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.