Sr. Thermal Test Engineer, Semi

Tesla•Grand Rapids, MI

About The Position

Join our diverse, enthusiastic, and growing team of multi-disciplinary engineers at Tesla, where we accelerate the world's transition to sustainable abundance—creating an era of clean, plentiful energy for all. You'll contribute by validating the reliability, performance, and durability of thermal systems that form the backbone of our self-driving vehicles and AI technologies. These systems ensure efficient cooling for batteries, AI hardware, and components in autonomous driving, enabling reliable operation in real-world conditions. With opportunities to work across various development programs, you'll thrive in Tesla's innovative, fast-paced environment, often collaborating beyond your core role to drive progress. Lead hardware validation and testing for thermal management components and subsystems, including compressors, A/C lines, heat exchangers, hoses, coolant pumps, HVAC blowers, and electronic valves. Identify potential failure modes and collaborate with design partners to implement effective improvements

Requirements

Bachelor’s Degree in Mechanical Engineering, Mechatronics Engineering, or equivalent experience
Proficiency in coding for test automation and data post-processing, with hands-on experience in Python and/or C. Familiarity with pytest for maintaining robust automation codebases
Foundation in thermodynamics, including refrigeration and coolant systems
Knowledge of working principles for common thermal components, including operation, testing, and characterization
Experience with standard lab and test equipment, such as power supplies, DAQs, pressure transducers, flow meters, and temperature sensors
Experience in high-voltage and low-voltage component validation (e.g., inverters, power electronics, motors)
Prior work with CAN communication protocols and test setups
Design experience using CAD software such as CATIA or SOLIDWORKS
Background in full vehicle testing for thermal system validation, testing, and reliability

Responsibilities

Oversee the build and testing of thermal system test bucks, creating modular setups for component-, system-, and vehicle-level evaluations
Develop and maintain test software in Python for automation, data collection, analysis, and post-processing; refine our pytest-based automation codebase to interact with devices and support reliability testing
Design and build custom test fixtures to enable efficient, modular, and repeatable validation processes
Integrate test equipment such as power supplies, environmental chambers, DAQs, sensors, and related instrumentation into automated test setups, ensuring seamless connectivity and data accuracy for high-fidelity validation
Conduct hands-on debugging of test setups and equipment; perform root cause analysis on failures and issues affecting both test hardware and the device under test to enable rapid resolutions and iterative improvements
Manage the full testing lifecycle from setup to execution and reporting, including planning, development, inspections, root cause analysis, data processing, and full-vehicle interactions for software validation and thermal system reliability
Document test findings clearly and communicate them promptly to cross-functional teams; conduct root cause analysis on failures and partner with design,software, failure analysis, reliability teams, and suppliers to develop corrective actions
Track validation schedules, coordinate test resources, and update program managers on progress, risks, and blockers

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