Sr. CAE Engineer, Chassis Systems

About the role

The Chassis Design Engineering team is responsible for tires, wheels, hubs, halfshafts, steering, suspension, subframes, brakes, pedals/controls, and air suspension systems on all of Tesla’s passenger car and heavy vehicle programs. Delivering those systems depends on a deep understanding of engineering first principles and the ability to leverage finite element analysis early and often during the design process.

This is a hybrid role between a Mechanical Design Engineer and a CAE Analyst. You will analyze and optimize revolutionary vehicle designs never before executed, enabled by clean-sheet design methodology and Tesla’s innovative vehicle architecture. You will work as a generalist across chassis systems — structures at a minimum, and in-house development work such as actuators, steering gear, brakes, and related mechanisms as programs need it — and help build Chassis CAE methods and tools so the team can move faster with higher confidence.

At Tesla, you are empowered to push boundaries by working closely with all groups involved and help drive for the best overall outcome. Like other Mechanical Design Engineers on the team, you will operate end-to-end with engineering, supply chain, production, test, and service. Hands-on development work and production support are part of the job. Some travel to suppliers may be required, including international travel.

Responsibilities

• Developing highly predictive finite element models in collaboration with a small team of design engineers
• Performing modal, linear/non-linear, durability/fatigue, random vibration, NVH CAE and crash analysis to evaluate components across various chassis sub-systems and recommend design solutions that balance the needs of engineering, suppliers, and program management
• Using first principle thinking and structural optimization to meet/exceed performance metrics, while minimizing weight and cost
• Translating analysis into design direction; making small geometry changes in CAD and growing design ownership over time
• Developing and improving CAE methods, workflows, and tools for Chassis Engineering
• Working with reliability and test to develop load cases and cycle counts to be used for CAE and component level test in order to satisfy program and industry requirements
• Working with both internal and external testing groups for model verification and validation
• Resolving issues with cross-functional teams including engineering, supply chain, production, and service; participating in supplier technical reviews as needed

Requirements

• Degree with 3+ years of relevant industry experience
• Strong working knowledge of finite element analysis techniques, solid mechanics, structural dynamics and numerical methods
• Expert level component/system design analysis including modal, linear/non-linear static, durability/fatigue, random vibration, NVH CAE, and Crash analysis
• Experience with OptiStruct, Abaqus, LS-Dyna or similar FEM codes, nCode or equivalent fatigue post-processing and Matlab or Python for FEA pre/post-processing automation
• Familiarity within 3D CAD software, preferably CATIA V5/6; able to make small design changes
• Able to work under pressure while managing competing demands and tight deadlines
• Ability to come up with practical and theoretically sound solutions to problems never encountered before
• Prior work on chassis structures, suspension, steering, brakes, or electromechanical actuators
• Hands-on prototype, lab, or production troubleshooting experience

Benefits

• Medical plans with plan options including $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both with options for $0 paycheck contribution
• Company-paid Health Savings Account (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 including 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

Pay

Expected compensation: $91,600 - $316,800/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.