Sr. Mechanical Design Simulation Engineer

Sr. Mechanical Design Simulation Engineer Tesla - 3.3 Fremont, CA Job Details Full-time $91,600 - $234,000 a year 3 hours ago Benefits Commuter assistance Health savings account AD&D insurance Paid holidays Disability insurance Health insurance Dental insurance Flexible spending account Flextime Adoption assistance Employee assistance program 401(k) matching Employee discount Benefits from day one Pet insurance Qualifications CAD software Computational fluid dynamics (CFD) Automation Regulatory compliance Geometry Productivity software Simulation systems Local building codes Building information modeling (BIM) tools Research & development Engineering validation Full Job Description What to Expect Tesla's Infrastructure Design team leads the development of innovative solutions for complex R D and manufacturing facilities across the Bay Area and beyond. We specialize in creating sophisticated infrastructure systems that power next-generation research and production environments. As a Mechanical Design Simulation Engineer, you will work closely with Mechanical design engineers to optimize designs and reduce costs. This role requires expertise in both technical leadership and creative problem solving in order to break down problems to their most basic components and quickly iterate on wide range of possible solutions. This role will move us beyond conservative design practices to achieve significant cost savings, increase system performance, and ensure superior safety and regulatory compliance using high-fidelity CFD modeling. What You'll Do Lead the development, validation, and maintenance of high-fidelity, steady-state, and transient Computational Fluid Dynamics (CFD) models for complex, multi-physics laboratory systems Optimize the design of high-plume lab exhaust stacks and general lab HVAC systems to ensure ACGIH-compliant capture velocity and superior containment while minimizing fan and duct sizing (reducing CapEx and OpEx) Analyze complex air distribution, conditioning, and thermal uniformity within vehicle environmental and thermal test cells Establish robust correlation and validation practices, comparing CFD results with experimental test data (e.g., pitot tube traverses, thermal sensor arrays) to ensure model predictive accuracy Pioneer and standardize best practices and internal templates for all CFD and thermal-fluid analysis across the engineering team Partner with the Programming Engineer on the ID3 team to develop custom automation tools, optimization algorithms, and scripting (Python, MATLAB, etc.) to streamline the CFD workflow, reduce analysis turnaround time, and integrate results directly into design tools Utilize advanced techniques like Design of Experiments (DOE) and parametric optimization driven by simulation data to provide clear, actionable design recommendations that drive down system costs and energy usage Serve as the internal subject matter expert, providing expert consulting to design engineers, design managers, and research scientists/engineers Mentor and technically guide mid-level and junior engineers in the application of thermal-fluid principles and CFD software to grow internal capabilities Translate complex simulation data into clear, concise, and executive-ready reports and presentations, justifying design choices and capital investment What You'll Bring Master's Degree in Mechanical, Aerospace, Chemical Engineering, or a related discipline with a specialization in fluid dynamics or heat transfer, or the equivalent in experience 10+ years of professional experience utilizing CFD in an industrial or advanced R D environment, with a strong preference for experience in HVAC, critical ventilation, or lab/facility design Expert-level proficiency with commercial CFD software packages such as ANSYS Fluent, Simcenter STAR-CCM+, or OpenFOAM Proven experience with one or more of the following specialized areas: High-fidelity Conjugate Heat Transfer (CHT) modeling, Species transport, fire/combustion modeling, thermal runaway phenomena, or HVAC systems, indoor air quality (IAQ), and contaminant dispersion analysis. Strong proficiency in scripting languages for pre/post-processing and automation (e.g., Python, MATLAB) Experience correlating and validating CFD models with physical test data from vehicle and battery testing environments, or other similar experiments Familiarity with building codes, T24, ASHRAE, and ACGIH guidelines Experience with CAD/Geometry manipulation and meshing tools (e.g., ANSYS SpaceClaim, HyperMesh, ANSa) and integrating geomotries from Revit, AutoCAD, Bluebeam, Microsoft Office Suite and Building Information Modeling (BIM) Experience running large simulations on clusters, parallel processing setup, and knowing when a detailed CFD model is overkill vs. when it's essential Communication skills - can clearly present results to non-technical stakeholders Compensation and Benefits 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 $91,600 - $234,000/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. Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws. Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.