Internship, Mechanical Design Engineer, Autonomous Charging, Energy Engineering (Winter/Spring 2027)

About the role

This internship is expected to start January 2027 and continue through the Winter/Spring term (through April/May 2026) or into Summer 2027 if available. A minimum commitment of 12 weeks, full-time (40 hours/week) on‑site is required. Located in Palo Alto, CA, the role is part of Tesla’s year‑round program that places students in projects critical to team success, working on novel electromechanical systems for vehicle and supercharger product lines within the Autonomous Charging team.

Responsibilities

• Design electromechanical assemblies for vehicle and supercharger product lines, including actuators, thermal solutions, structural enclosures, and electrical interconnects.
• Perform mechanical design analysis including thermal FEA/CFD, structures, kinematics, statics, and vibrations.
• Create 3D designs of complex parts and assemblies using CATIA 3DX and produce 2D drawings with GD&T.
• Collaborate with stakeholders to integrate assemblies into vehicle and supercharger architectures.
• Solve complex packaging challenges requiring high‑voltage insulation, IP67+ sealing, EMI performance, and mechanical shock/loading robustness while maintaining manufacturability.
• Support hands‑on prototyping and system‑level testing; develop test plans and execute them.
• Own basic testing and analysis; support advanced testing and analysis.
• Root‑cause test failures and production problems.
• Collaborate with manufacturing, testing, NPI, and supply chain teams.

Requirements

• Currently pursuing a degree in Mechanical Engineering, Mechatronics, Physics, or a related field.
• Strong mechanical engineering fundamentals and physics‑based first‑principles problem solving.
• Knowledge of GD&T, finite element analysis, and design for reliability concepts.
• Experience with CATIA V5 and/or V6; familiarity with PLM systems a plus.
• Basic understanding of electrical design fundamentals — high‑voltage isolation, power electronics, thermal management, and interconnect design (a plus).
• Basic understanding of material science of components used in mechanical design (metals, insulators, plastics, connectors, gaskets).
• Desire to own a lot and work hard; detail‑oriented with solid documentation and reporting skills.
• Experience with student Formula Vehicle, Solar Car, Baja, etc. a plus.
• Strong organization, written, and verbal communication skills.

Benefits

• Medical plans with $0 payroll deduction options.
• Family‑building, fertility, adoption and surrogacy benefits.
• Dental (including orthodontic) and vision plans, both with $0 payroll contribution option.
• Company‑paid HSA contribution when enrolled in the High Deductible Medical Plan with HSA.
• Healthcare and Dependent Care Flexible Spending Accounts (FSA).
• 401(k), Employee Stock Purchase Plans, and other financial benefits.
• Company‑paid Basic Life, AD&D, and short‑term disability insurance (90‑day waiting period).
• Employee Assistance Program.
• Sick and vacation time (flex time for salary positions) and paid holidays.
• Back‑up childcare and parenting support resources.
• Voluntary benefits: critical illness, hospital indemnity, accident insurance, theft & legal services, pet insurance.
• Commuter benefits.
• Employee discounts and perks program.

Pay

Expected compensation: $20.00 – $50.00 per hour, plus benefits. Pay offered may vary depending on market location, job‑related knowledge, skills, and experience. The total compensation package may also include other elements dependent on the position offered.