Sr. Mechanical Design Engineer, Power Semiconductor Packaging
Tesla Motors, Inc., Palo Alto, CA, United States
What to Expect
As a Mechanical Design Engineer for Power Semiconductor Packaging, you won't just follow industry standards—you'll set them. Tesla has already revolutionized power discrete and module, making our designs the global gold standard. Forget the constraints of traditional \"off-the-shelf\" outlines, you will use a first-principles approach to design custom packaging for our next-generation vehicle and energy products. Your scope is end-to-end: from sketching the first concept to overseeing high-volume mass production. You will create novel, world-class packaging solutions that solve complex structural, thermal, and electrical challenges. Drive prototype builds, rigorous engineering testing, and final validation. Work within a fast-paced, multi-disciplinary team that blends mechanical, thermal, and electrical engineering.
What You'll Do
Develop Tesla custom power semiconductor packages (e.g., discrete and module) for electric vehicle and energy storage products utilizing SiC/ Gan/ or Si technology as well as developing novel cooling and attachment methods for Power Electronics applications
Lead package development efforts and collaborate with electrical architecture teams as well as product design team to define requirements, performance and qualifications plans
Conduct root cause analysis of failures with coordination from failure analysis and reliability teams to improve design and enhance package reliability
Conduct Multi-physics simulations to extract parasitic resistance/inductance/capacitance and thermal resistance stacks of semiconductor packages to develop fast-switching and low-loss design to maximize system reliability
Perform lab evaluation and sample construction using hand tools or semi-manual equipment
Deliver technical writing, presentation and training sessions
What You'll Bring
Master's Degree in Mechanical Engineering or Power Electronics Engineering focusing on semiconductor packaging, or equivalent experience
Minimum 3 years of industry experience of semiconductor packaging design and development
Extensive knowledge of various manufacturing techniques, including die bonding, wire bonding, solder dispensing & printing, reflow, plasma cleaning, encapsulation, plating, stamping, die-casting, injection molding, fastening/joining, and automated assembly processes, to ensure designs are productionable. As well as familiarity with PCBAs and their components
Proficiency in multi-physics simulation ranging from thermal, electrical, mechanical, and magnetic design. Finite element analysis (FEA) tools like ANSYS Workbench, Icepak, Q3D, CFD
Proficiency in 2D/3D CAD drawing using CATIA V5/V6, Solidworks, AutoCAD
Deep understanding of packaging materials, processes, failure modes, failure analysis approaches, and qualification standards for automotive products
Basic understanding of power device physics, power electronic circuits, and high-voltage insulation
Strong knowledge of tolerance stacks, design for manufacturing (DFM), design for test (DFT), and design for reliability
Strong technical writing and presentation skills
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
$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.
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As a Mechanical Design Engineer for Power Semiconductor Packaging, you won't just follow industry standards—you'll set them. Tesla has already revolutionized power discrete and module, making our designs the global gold standard. Forget the constraints of traditional \"off-the-shelf\" outlines, you will use a first-principles approach to design custom packaging for our next-generation vehicle and energy products. Your scope is end-to-end: from sketching the first concept to overseeing high-volume mass production. You will create novel, world-class packaging solutions that solve complex structural, thermal, and electrical challenges. Drive prototype builds, rigorous engineering testing, and final validation. Work within a fast-paced, multi-disciplinary team that blends mechanical, thermal, and electrical engineering.
What You'll Do
Develop Tesla custom power semiconductor packages (e.g., discrete and module) for electric vehicle and energy storage products utilizing SiC/ Gan/ or Si technology as well as developing novel cooling and attachment methods for Power Electronics applications
Lead package development efforts and collaborate with electrical architecture teams as well as product design team to define requirements, performance and qualifications plans
Conduct root cause analysis of failures with coordination from failure analysis and reliability teams to improve design and enhance package reliability
Conduct Multi-physics simulations to extract parasitic resistance/inductance/capacitance and thermal resistance stacks of semiconductor packages to develop fast-switching and low-loss design to maximize system reliability
Perform lab evaluation and sample construction using hand tools or semi-manual equipment
Deliver technical writing, presentation and training sessions
What You'll Bring
Master's Degree in Mechanical Engineering or Power Electronics Engineering focusing on semiconductor packaging, or equivalent experience
Minimum 3 years of industry experience of semiconductor packaging design and development
Extensive knowledge of various manufacturing techniques, including die bonding, wire bonding, solder dispensing & printing, reflow, plasma cleaning, encapsulation, plating, stamping, die-casting, injection molding, fastening/joining, and automated assembly processes, to ensure designs are productionable. As well as familiarity with PCBAs and their components
Proficiency in multi-physics simulation ranging from thermal, electrical, mechanical, and magnetic design. Finite element analysis (FEA) tools like ANSYS Workbench, Icepak, Q3D, CFD
Proficiency in 2D/3D CAD drawing using CATIA V5/V6, Solidworks, AutoCAD
Deep understanding of packaging materials, processes, failure modes, failure analysis approaches, and qualification standards for automotive products
Basic understanding of power device physics, power electronic circuits, and high-voltage insulation
Strong knowledge of tolerance stacks, design for manufacturing (DFM), design for test (DFT), and design for reliability
Strong technical writing and presentation skills
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
$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.
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