Systems Engineer, Optimus Robot Design Validation

Tesla is looking for a highly motivated Systems Engineer to validate the fidelity of manufactured Optimus robots to design intent and modeling from a kinematics, dynamics, and sensing perspective. You will work across cross-functional teams to develop and execute validation methodologies that ensure accuracy, precision, and repeatability at high volume - directly driving design improvements and closing the loop between simulation and real hardware. If you have a strong foundation in mechanical systems, metrology, and robotics, and a track record of translating physical measurements into actionable design changes, join Tesla to play a pivotal role in shaping the future of AI robotics.

Responsibilities

Work closely with Hardware, Software, and Simulation teams across the full product lifecycle - from initial concept and prototype builds through high-volume production to validate that manufactured robots conform to design intent and URDF specifications Validate robot link dimensional accuracy, mass properties, and range of motion using metrology tools including FARO arms, FARO laser trackers, CMM, structured light and laser 3D scanners, and fixture-based gauging, confirming production hardware matches CAD within tolerances Validate kinematic accuracy of differential linkages and joint mechanisms by measuring hardware across multiple poses and correlating expected versus measured angles, with and without load Develop and validate bot-level end effector and joint error models incorporating mechanical tolerances, calibration accuracy, backlash, datum variation, and vision system errors - validated on real hardware using OptiTrack, Vicon motion capture, FARO metrology, and fixture-based testing Feed production measurement data - including end effector errors, joint errors, stiffness, backlash, and friction - back to simulation and modeling teams to improve sim-to-real performance Develop and validate high-volume joint encoder calibration methodologies compatible with production cycle times, including end-stop, gauge block, fixture-based, vision-based, and IMU-based approaches Characterize calibration accuracy and repeatability across the robot fleet, exposing hardware design and quality issues that drive calibration errors and feeding findings back to design teams Design and execute validation studies - including GR&R studies, degradation studies, and fixture-based checks - to systematically identify and root cause kinematic and dynamic performance issues across robot generations Translate validation findings into concrete design change recommendations, partnering with Design Engineering to drive hardware improvements that improve accuracy, repeatability, and yield across the fleet Define and maintain validation test plans, metrology protocols, and documentation standards to support continuous improvement as the Optimus platform scales to high-volume production

Requirements

Degree in Engineering, or equivalent experience Proficiency in CAD tools (CATIA and AutoCAD preferred) and ability to interpret and validate against engineering drawings and URDF specifications Hands-on experience with metrology equipment including FARO arms, FARO laser trackers, CMM, structured light and laser 3D scanners, OptiTrack, and Vicon motion capture systems Proficiency in mechanical assembly and familiarity with joint mechanisms, linkages, fastener selection, and harness integration Proficiency in electrical integration, testing, and troubleshooting, including familiarity with communication protocols and control systems Experience designing and executing structured validation studies including GR&R, tolerance stack-up analysis, and Monte Carlo simulation Experience with robotics simulation platforms such as MuJoCo or Isaac Lab, and familiarity with robotics kinematics, URDF modeling, and sim-to-real validation concepts Experience transitioning products from prototype to production with a focus on measurement systems, process capability, and quality First-principles problem-solving mindset with a strong ability to connect physical measurements to root cause and design action Able to work under pressure while managing competing demands and tight deadlines using exemplary verbal and written communication skills; well-organized with meticulous attention to detail