Sr. Mechanical Design Engineer, Thermal Systems, Castings

The Castings Manufacturing Engineering Group is the part of the Materials Engineering Group responsible for the design, build, launch and handover of state of the art Casting lines and equipment currently used for vehicle and humanoid programs. This team is focusing on achieving the highest efficiency, manufacturing volume and safety while proving performance and documenting every aspect of the project for handover to sustaining.

In this role, you will lead the design, documentation, and implementation of a thermal management system that extracts heat generated in the casting process. Thermal balance is critical to a high yield and high-volume casting process with aggressive cycle times. The candidate is expected to have technical knowledge in thermal analysis and process cooling equipment design including industrial piping system design and standards.

• Lead thermal system and utility design to support casting manufacturing equipment while applying a first-principles approach to develop efficient and robust systems, including capacity and control methodology, vendor selection and bid packages, equipment concept designs and reviews, fabrication, acceptance testing, installation, commissioning and cross-functional handover
• Design and selection of components such as heat exchangers, cooling towers, pumps, valves, piping, and instruments for large and complex systems
• Provide supporting design validation analysis (FMEA, FEA, CFD, etc.) and detailed build to print models/drawings for fabrication
• Establish operational performance metrics for thermal control
• Conduct flow rate, pressure drop and optimal piping design studies
• Create and manage large, detailed 3D CAD layouts used to locate equipment, support utilities, create utility routings, and support virtual commissioning.
• Oversee technical and schedule performance of equipment suppliers following Tesla standards and project roadmap.
• Create documentation needed to sustain operation of the equipment, including start up and shut down procedures, operation instructions, KPI’s, troubleshooting manuals, maintenance schedules, assembly drawings with BOM, fabrication drawings, etc.

• Degree in Mechanical Engineering or equivalent experience
• 5+ years of experience designing manufacturing lines, mechanical equipment, fixturing and tooling in 2D and 3D CAD (SolidWorks/Catia/Siemens NX/Revit/AutoCAD or similar)
• Competence in ISO 12100 Safety Standards for risk assessment and safety of machinery
• Experience in machine safety, including ANSI B11, RIA R15.06, ISO 13849
• Competence in process piping codes ASTM B31
• Competent in water treatment and quality monitoring processes
• Experience in simulation to validate design meets operational requirements (FEA, CFD, Transient Thermal)
• Proven project management experience of $1M+ capex projects with cost benefit analysis development
• Strong verbal and written communication skills able to lead technical reviews