Internship, Mechanical Design Engineer, Vehicle Power Electronics, Energy Engineering (Winter/Spring 2027)

Consider before submitting an application:

This position is expected to start January 2027 and continue through the entire Winter/Spring term (i.e through April/May 2027) or into Summer 2027 if available. We ask for a minimum of 12 weeks, full-time (40 hours/week) and on-site, for most internships.

International Students: If your work authorization is through CPT, please consult your school before applying. You must be able to work 40 hours per week. Many students will be limited to part-time during the academic year.

The Internship Recruiting Team is driven by the passion to recognize and develop emerging talent. Our year-round program places the best students in positions where they will grow technically, professionally, and personally through their experience working closely with their Manager, Mentor, and team. We are dedicated to providing an experience that allows the intern to experience life at Tesla by including them in projects that are critical to their team’s success.

As a Mechanical Design Engineer in Tesla's Vehicle Power Electronics team, you will design cutting edge, world-class power converters in use across the entirety Tesla vehicle lineup (Model 3/Y, Cybertruck, Semi, Cybercab, Roadster, and next generation vehicle platforms).  You will be joining an elite team of driven engineers with a huge scope, reach, and potential impact. Our power electronics products are critical components in electric and autonomous transportation (and AI data centers).

We are hardcore. The work is fast-paced and challenging.  Tesla’s mission and vision must excite you.

Power electronics is unique.  Despite its name, it pushes the limits of the wide breadth of mechanical engineering.  You will be required to know and apply statics & dynamics, fluids & thermals, mechanics & vibration, and more.  Our work is highly multi-disciplinary and you will be expected to know or learn basic electrical and magnetic physics, material science, statistics, and advanced manufacturing techniques.  Strong design skills, a ‘first-principles’ approach to problem solving, curiosity to learn and drive to develop/grow are must-haves.

At Tesla, our design work doesn't only exist on a computer screen and we don’t waste time on products that we don’t see a future in.  Your designs will come to life and exist in the real world within industry record time.  Design engineers will drive prototype builds, engineering testing, and validation of our products.  Your day-to-day tasks will involve design, analysis, and testing of all structural, thermal, environmental, and insulating aspects of converter components and their electrical connections.  An example would be the detailed design of custom magnetic components such inductors or transformers or high-performance heat exchangers.  You will own the design from conception thru its full evolution to mass-production.

Location: Palo Alto, CA

- Modeling and design of electro-mechanical parts and assemblies including plastics, sheet metal, heat sinks, insulation systems, magnetic components, high voltage connectors, fasteners, and other components
- Mechanical design analysis including thermal, CFD, structural, design for assembly, and design for test
- Collaborate with program stakeholders to integrate designs into vehicles, energy products, AI data centers, and more
- Solve electronics packaging issues: electrical isolation, sealing, thermal management, interconnection, shock and vibration management, electromagnetic interference (EMI), RF communications, etc.
- Develop engineering test plans for designs
- Create drawing packages and manufacturing instructions for parts and assemblies
- Assist in engineering prototype builds and component fabrication
- Collaborate with other mechanical, systems, electrical, magnetic, digital control, manufacturing, industrial design, and test engineers to take designs from concept through prototype to mass production

- Pursing a degree in Engineering, Power Electronics, Mechanical Engineering, or related field
- Experience designing packaging for electronic assemblies including in-depth understanding of relevant component fabrication processes
- Deep understanding of material science of components used in mechanical design (metals, insulators, plastics, connectors, gaskets, thermal interface materials, potting, etc.)
- Proficiency using 3D mechanical design and analysis tools (CATIA, ANSYS Icepak, StarCCM)
- Excellent communication skills and ability to work in a fast-paced and challenging environment
- Knowledge of GD&T, finite element analysis, and design for reliability concepts
- Experience using CATIA V5 and/or V6
- Experience with PLM systems, engineering changes, deviations, BOM structuring, etc.
- Working knowledge of Matlab, Python and ANYSYS
- Experience with environmental, reliability, safety, and industry standard requirements for automotive, industrial & residential products
- Basic understanding of electrical design fundamentals
- Experience with high volume manufacturing processes such as injection molding, stamping, diecast, etc.
- Familiarity with PCBAs and PCBA components

Benefits

As a full-time Tesla Intern, you will be eligible for:

- Medical plans > plan options with $0 payroll deduction
- Family-building, fertility, adoption and surrogacy benefits
- Dental (including orthodontic coverage) and vision plans. Both have an option with a $0 payroll 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), 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 to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
- Commuter benefits
- Employee discounts and perks program
Expected Compensation $20.00 - $50.00 + 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.