Staff Simulation Engineer
Tesla, Palo Alto, CA, United States
What to Expect
Tesla isseekinga highly skilled and analytical Battery Cell Simulation Engineer to join ourBattery Cell - Supplier Industrialization Engineering team. The ideal candidate will specialize in developing and applying multi-physics simulation models that bridge the gap between battery cell manufacturing processes and the resulting electrochemical, mechanical, and thermal failure modes. This role is critical in enabling predictive quality assurance, process optimization, andfailuremitigation in next-generationbattery cells.You will work at the intersection of materials science, manufacturing engineering, and computational modeling toidentifyprocess-induced defects (e.g., electrode misalignment,winding/stacking process variation,particle agglomeration, electrolyte distribution anomalies) and simulate their impact on cell performance, longevity, and safety.
What You'll Do
Develop andvalidatefiniteelements(FE), computational fluid dynamics (CFD), and electrochemical-thermal (EC-TH) simulation models to predict how manufacturing parameters (e.g., coating thickness, drying temperature,calendaringpressure, winding tension) influence internal cell architecture and degradation mechanisms
Establish digital twins of battery cell manufacturing processes (e.g., slurry mixing, coating, drying, calendaring, winding, stacking, electrolyte filling) to simulate process variability and its downstream effects on cell reliability
Correlate simulation results with experimental data from lab-scale and pilot-line production (e.g., X-ray CT, SEM, EIS, cycle testing, abuse testing) to refine models and improve predictive accuracy
Identifyand model root causes of common failure modes such as lithium plating, internal short circuits, mechanical stress cracking, electrolyte dry-out, and capacity fade-tracing them back to specific process steps
Collaborate with process engineers, materials scientists, and test teams to translate simulation insights into actionable process improvements and quality control criteria
Lead the development of simulation-based design of experiments (DoE) frameworks to optimize manufacturing parameters while minimizing failure risk
What You'll Bring
Master's or PhD in Mechanical Engineering, Materials Science, Chemical Engineering, Physics, ora related field, or equivalent experience
8+ years of experience in battery cell simulation or manufacturing process modeling (preferably in lithium-ion batteries)
Proficiencyin simulation tools such as ANSYS, COMSOL Multiphysics, Abaqus,FEniCS, orOpenFOAM
Strong understanding of electrochemical reaction kinetics, solid-state diffusion, and thermal-mechanical behavior in battery cells
Experience withMultiphysicscoupling (thermal-electrochemical-mechanical) modeling
Familiarity with battery cell manufacturing processes (coating, drying,calendaring, winding, sealing, electrolyte injection)
Strong programming skills in Python, MATLAB, or C++ for automation, post-processing, and model calibration
Demonstrated ability to interpret experimental data and use it tovalidateand refine simulation models
Compensation and Benefits
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 $152,000 - $264,000/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 isseekinga highly skilled and analytical Battery Cell Simulation Engineer to join ourBattery Cell - Supplier Industrialization Engineering team. The ideal candidate will specialize in developing and applying multi-physics simulation models that bridge the gap between battery cell manufacturing processes and the resulting electrochemical, mechanical, and thermal failure modes. This role is critical in enabling predictive quality assurance, process optimization, andfailuremitigation in next-generationbattery cells.You will work at the intersection of materials science, manufacturing engineering, and computational modeling toidentifyprocess-induced defects (e.g., electrode misalignment,winding/stacking process variation,particle agglomeration, electrolyte distribution anomalies) and simulate their impact on cell performance, longevity, and safety.
What You'll Do
Develop andvalidatefiniteelements(FE), computational fluid dynamics (CFD), and electrochemical-thermal (EC-TH) simulation models to predict how manufacturing parameters (e.g., coating thickness, drying temperature,calendaringpressure, winding tension) influence internal cell architecture and degradation mechanisms
Establish digital twins of battery cell manufacturing processes (e.g., slurry mixing, coating, drying, calendaring, winding, stacking, electrolyte filling) to simulate process variability and its downstream effects on cell reliability
Correlate simulation results with experimental data from lab-scale and pilot-line production (e.g., X-ray CT, SEM, EIS, cycle testing, abuse testing) to refine models and improve predictive accuracy
Identifyand model root causes of common failure modes such as lithium plating, internal short circuits, mechanical stress cracking, electrolyte dry-out, and capacity fade-tracing them back to specific process steps
Collaborate with process engineers, materials scientists, and test teams to translate simulation insights into actionable process improvements and quality control criteria
Lead the development of simulation-based design of experiments (DoE) frameworks to optimize manufacturing parameters while minimizing failure risk
What You'll Bring
Master's or PhD in Mechanical Engineering, Materials Science, Chemical Engineering, Physics, ora related field, or equivalent experience
8+ years of experience in battery cell simulation or manufacturing process modeling (preferably in lithium-ion batteries)
Proficiencyin simulation tools such as ANSYS, COMSOL Multiphysics, Abaqus,FEniCS, orOpenFOAM
Strong understanding of electrochemical reaction kinetics, solid-state diffusion, and thermal-mechanical behavior in battery cells
Experience withMultiphysicscoupling (thermal-electrochemical-mechanical) modeling
Familiarity with battery cell manufacturing processes (coating, drying,calendaring, winding, sealing, electrolyte injection)
Strong programming skills in Python, MATLAB, or C++ for automation, post-processing, and model calibration
Demonstrated ability to interpret experimental data and use it tovalidateand refine simulation models
Compensation and Benefits
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 $152,000 - $264,000/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.