Robotics Mechanical Design Engineer, Gears, Optimus

Tesla’s actuator team designs and builds actuators for humanoid bi-pedal robots (Tesla Bot). The team integrates mechanical, electrical, and electromagnetic engineering disciplines in a collaborative environment. This role focuses on the design, optimization, and industrialization of high-performance gear systems for electromechanical actuators. You will contribute to gear design efforts to achieve exceptional torque density, efficiency, and reliability in rotary and linear actuator applications.

Responsibilities

Design and optimize gear trains for torque and force density in rotary/linear actuator systems Collaborate with electromagnetic motor teams to align gear systems with motor performance goals Evaluate and implement advanced gear technologies (e.g., planetary, cycloidal, harmonic drives) for efficiency and reliability Develop prototypes for validating gear system performance under dynamic loads Conduct thermal, stress, and wear analysis to ensure gear durability and reliability Partner with manufacturing and supply chain teams to refine gear production processes Troubleshoot and resolve gear-related performance issues during prototyping and production Document gear design specifications and test results for iterative improvement Explore novel gear configurations to reduce weight, cost, and complexity Support validation of gear systems against actuator-level efficiency and torque requirements

Requirements

Degree in Mechanical Engineering or related field with expertise in gear design, or equivalent experience (advanced degree preferred) 3+ years designing rotary/linear gear systems for high-torque electromechanical applications Proven experience in gear train optimization for efficiency, durability, and force density Proficiency in CAD tools (e.g., SolidWorks, CATIA) for gear system design Deep understanding of planetary, cycloidal, harmonic, and ball screw gear mechanisms Experience with finite element analysis (FEA) or computational modeling for gear systems Knowledge in common tools like, MASTA, ROMAX, Transmission 3D, etc. Familiarity with gear manufacturing processes (e.g., hobbing, grinding, 3D printing) Strong analytical skills in thermal management and mechanical stress analysis Hands-on experience with gear prototyping, testing, and calibration and knowledge of industry standards (e.g., AGMA, ISO) for gear design and quality