Demo

Sr. Mechanical Design Engineer, Aerodynamic Prototypes, New Program Engineering

Tesla Motors, Inc.
Hawthorne, CA Full Time
POSTED ON 6/7/2026
AVAILABLE BEFORE 7/6/2026
What to Expect

The Sr. Mechanical Design Engineer role within the Aerodynamic Prototype team will lead the design, build & test of physical models in coordination with the Aerodynamics Engineering team. Tesla places a strong emphasis on vehicle aerodynamic optimization, not only for efficiency & range, but for wind noise as well. Our group works closely with Design & other engineering groups to achieve maximum performance with minimal compromise to other attributes.

The Aerodynamic Prototype team is small, highly motivated & thrives in a rapid engineering environment. This role offers the rare opportunity to participate in the development of new & genuinely cutting-edge vehicles. You must have a genuine passion for engineering the best EVs in the world.


What You'll Do
  • Lead the design & create build plans for wind tunnel models that align with the aerodynamicists' test plans & program deliverables
  • Execute build plans by designing, releasing & coordinating the build of test properties for wind tunnel & on-vehicle tests
  • Perform hand calculations & FEA to justify mechanical design decisions for models and ensure structural performance of physical asset
  • Work with engineers, suppliers, model makers & fabricators to create, assemble, instrument & test high fidelity wind tunnel models & physical mockups
  • Lead innovation efforts to develop & improve processes continuously
  • Mentor & support team members and interns through brainstorming sessions and technical design reviews

What You'll Bring
  • Degree in Mechanical Engineering or equivalent with minimum of 5 years of equivalent experience in a product development environment
  • Demonstrated proficiency with Finite Element Analysis (FEA), ability to interpret CAE results and integrate recommendations into product designs
  • Effectively handle multiple priorities, organize workloads, and meet tight delivery timelines. Create schedules and report to leadership how the early design decisions track to critical program level milestones
  • Proficiency in CAD (Computer Aided Design) software using parametric elements and knowledge-based engineering tools
  • Detail-oriented personality with effective documentation and reporting
  • Excellent communicator, resourceful, and mindful of time management
  • Must be proactive in improving processes & driving projects, examples of this should be provided
  • Familiarity with common aerodynamic measurement systems like pressure sensing & load cell hardware
  • Experience with track testing or wind tunnel testing, either at model or full scale preferred
  • Must be willing to travel 10% of working days to support on track & tunnel testing

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
    $104,120 - $222,300/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.

     

    Salary : $104,120 - $222,300

    If your compensation planning software is too rigid to deploy winning incentive strategies, it’s time to find an adaptable solution. Compensation Planning
    Enhance your organization's compensation strategy with salary data sets that HR and team managers can use to pay your staff right. Surveys & Data Sets

    What is the career path for a Sr. Mechanical Design Engineer, Aerodynamic Prototypes, New Program Engineering?

    Sign up to receive alerts about other jobs on the Sr. Mechanical Design Engineer, Aerodynamic Prototypes, New Program Engineering career path by checking the boxes next to the positions that interest you.
    Income Estimation: 
    $108,186 - $133,193
    Income Estimation: 
    $134,236 - $174,128
    Income Estimation: 
    $132,162 - $161,329
    Income Estimation: 
    $108,186 - $133,193
    Income Estimation: 
    $134,236 - $174,128
    Income Estimation: 
    $132,162 - $161,329
    Employees: Get a Salary Increase
    View Core, Job Family, and Industry Job Skills and Competency Data for more than 15,000 Job Titles Skills Library

    Job openings at Tesla Motors, Inc.

    • Tesla Motors, Inc. Sparks, NV
    • What to Expect Tesla's Finance team integrates traditional financial planning and analysis with strategic business decision-making, directly supporting Tes... more
    • 1 Day Ago

    • Tesla Motors, Inc. Sparks, NV
    • What to Expect Tesla is seeking an ambitious Environmental Health & Safety Technician to support our team in Semi Factory Nevada. This role will support da... more
    • 1 Day Ago

    • Tesla Motors, Inc. Sparks, NV
    • What to Expect We are seeking a Senior Technical Program Manager to lead operations programs at Semi Factory Nevada. This role is central to driving seamle... more
    • 1 Day Ago

    • Tesla Motors, Inc. Phoenix, AZ
    • What to Expect The Tesla Rental Program is looking for a Rental Readiness Specialist to work on one of the most progressive vehicle brands in the world. Th... more
    • 1 Day Ago


    Not the job you're looking for? Here are some other Sr. Mechanical Design Engineer, Aerodynamic Prototypes, New Program Engineering jobs in the Hawthorne, CA area that may be a better fit.

    • Tesla Hawthorne, CA
    • What to Expect The Sr. Mechanical Design Engineer role within the Aerodynamic Prototype team will lead the design, build & test of physical models in coord... more
    • 1 Day Ago

    • Image Engineering Valencia, CA
    • Description Image Engineering was founded as a company that pushes boundaries, develops new ideas through design, engineering and fabrication, and is a lea... more
    • 1 Month Ago

    AI Assistant is available now!

    Feel free to start your new journey!