Sr. Manufacturing Engineer, High Speed Stamping

In this role, you will support the program lead from feasibility through a process that is feasible for high-speed stamping of laminated segment stators on the Stamping Manufacturing Engineering team. You will own progressive die design and set die standards, process parameters and quality controls from concept through production launch, working with motor design, tooling and die suppliers. This work makes stator laminations manufacturable at the rate and quality required for Tesla electric drive units.

- Support the program lead from feasibility through making the process feasible for high-speed stamping
- Develop strip layout, material flow and process capability for laminated segment stator stamping
- Own progressive and compound die design for thin-gauge electrical steel, including segment geometry, interlocking and stack bonding
- Set die design standards, tolerancing and tooling specifications for high strokes-per-minute lines
- Work with motor design in concept development so slot profiles, segment interfaces and lamination geometry are manufacturable
- Define and validate feed rate, blankholder force, lubrication and die clearance for thin-gauge electrical steel
- Manage supplier die programs from RFQ and design review through tryout and production approval
- Lead PFMEA and DFMEA and put countermeasures into die design and process controls
- Define quality plans for geometry, burr height, flatness and interlock integrity, with SPC at high volume
- Specify presses, coil handling and in-line inspection, and support tryout, commissioning and ramp at suppliers and Tesla sites

- Degree in Mechanical Engineering, Manufacturing Engineering or equivalent experience
- 5 years of relevant stamping experience, or 3 years with a degree
- Progressive die design for high-speed stamping, including strip layout, station sequencing and components such as punches, dies, pilots, lifters and cams
- Electrical steel stamping, including thin-gauge behavior, springback and burr control
- Stator lamination or laminated core manufacturing, including segment geometry, interlocking and stack assembly
- High-speed press operations at 200 strokes per minute or above, in cluding press selection, dynamic load and coil feed integration
- GD&T for tooling and lamination drawings, PFMEA, DFMEA and die CAD in CATIA, NX or equivalent
- Preferred: traction motor segment stators, self-bonding or mechanical interlock, in-die sensing and forming simulation in AutoForm, Dynaform or Simufact
- Essential physical demands: work on the factory floor around stamping equipment, support die tryouts and travel up to 25% to suppliers and Tesla sites

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
- Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)