Lead Mechanical Design Engineer, Power Electronics (m/f/d)
First seen by Alion on Oct 8, 2026.
### What to Expect
Please not: roles are open at multiple seniority levels for demonstrated excellence.At Tesla Engineering Germany in Freiburg, we're building the future of sustainable energy by developing innovative power electronics for energy storage and vehicle charging systems. You will own the cradle-to-grave mechanical design of tightly integrated, high-volume electromechanical systems, from first concept through prototyping and validation to mass production. You'll work closely with Electrical, Product, Reliability, Manufacturing, and Supply Chain teams. This is an opportunity to own key projects, use modern tools, and work in state-of-the-art facilities on power electronics that ship in Tesla products worldwide. Your work contributes directly to the world's transition to sustainable energy. At the lead level, you will also set technical direction and guide a small team of mechanical engineers.
### What You’ll Do
- Own the electromechanical design of injection-molded plastics, sheet metal, high-pressure die castings, heat sinks / cold plates, insulation systems, magnetics, HV/LV interconnects, busbars, and PCBA-adjacent structures
- Solve electronics packaging end-to-end: thermal management, high-voltage insulation (creepage/clearance), IP67+ sealing, EMI, shock/vibration, and long-term environmental reliability
- Lead track: Serve as technical owner of a product line, mentor 3–4+ engineers, lead and approve design reviews, and enforce technical rigor and schedule discipline
- Analyze before you cut metal: thermal / CFD, structural FEA, tolerance stacks, DFM / DFA / DFR, and DFMEA where it matters
- Design custom magnetics and power interfaces (inductors, transformers, chokes, terminals) as first-class mechanical products, not afterthoughts
- Partner with electrical, systems, reliability, manufacturing, supply chain, and compliance teams, and design against UL / IEC / GB standards through to certification
- Drive prototypes into reality: builds, test support, characterization, design verification, and root-cause analysis of failures
- Release for production in CATIA 3DEXPERIENCE: 3D models, 2D drawings with GD&T, PLM / ECOs / BOMs, and supplier collaboration for automated manufacturing at thousands of units per week
### What You’ll Bring
- Bachelor's degree or higher in Mechanical Engineering, or equivalent experience; Master’s degree preferred for senior/ staff/ lead level
- Strong mechanical fundamentals and a physics-based, first-principles approach to structural and thermal problems
- Proven product design ownership from concept to scaled production (portfolio preferred)
- Lead track: 7+ years of relevant product design experience, including 2+ years of design leadership
- Fluency in CATIA V5 / 3DEXPERIENCE, GD&T, tolerance analysis, and design for high-volume processes (molding, stamping, die casting, fastening, joining, dispensing)
- Ability to run, or critically review, thermal / CFD / structural analysis, plus working knowledge of power electronics components (PCBAs, MOSFETs, inductors, transformers)
- Detail-oriented, with clear written and verbal communication in English and the ability to thrive in a fast-paced environment Highly valued:
- Direct experience in power electronics packaging: inverters, chargers, DC-DC, magnetics, busbars, or HV semiconductor modules
- Experience designing against certification standards (UL, IEC, GB) and obtaining certificates
- Multiphysics intuition: heat transfer, fluids, mechanics, and materials (magnetics a strong plus)
- MATLAB / Python for data reduction, scripting, or reduced-order thermal models
- PLM / change control / BOM discipline in a fast-moving product environment
- Hands-on lab instinct: you would rather instrument a prototype than argue from a slide
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.
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Apply at: https://www.tesla.com/careers/search/job/286009?source=BA