Mechanical Design Engineer, Exteriors

About the role

As a Mechanical Design Engineer on the Exterior Engineering Team, you will design, prototype, validate, and launch exterior components for current and future vehicle programs. You will work on a diverse family of parts, from front and rear fascia assemblies to underbody and trim components, collaborating closely with styling, manufacturing, and supplier teams.

Key responsibilities

• Concept engineering, feasibility studies, and packaging within vehicle architecture.
• Design exterior systems to meet targets for craftsmanship, function, cost, and weight.
• Iterate with the Tesla design/styling studio to balance form, function, and cost.
• Detail design including surface development, structural analysis, datum strategy, attachments, and GD&T.
• Apply DFSS methodologies throughout design, validation, and launch phases.
• Interpret CAE simulation results and integrate recommendations into product designs.
• Collaborate with suppliers on DFM, MoldFlow, tooling design, and injection trials.
• Work with plastics engineering to optimize part layout for assembly and paint lines.
• Coordinate with Vehicle Engineering, Manufacturing Engineering, and Procurement to ensure manufacturability, assembly feasibility, and serviceability.

Required profile

• Bachelor’s degree in Mechanical Engineering or equivalent experience.
• Proficiency with Catia V5/V6 (or other CAD tools) and strong mechanical engineering fundamentals.
• Knowledge of large‑plastic part design, painting, injection molding, stamping, casting, and composites.
• Experience guiding a part from concept through tooling release to production launch.
• Proven ability to manage suppliers during product development.
• Understanding of design differences for low‑volume vs. high‑volume and entry‑level vs. premium vehicles.
• Hands‑on experience with DFSS methodologies in automotive programs.
• Familiarity with creating specifications, DFMEAs, DVP&Rs, and related technical documentation.

Required skills

• Catia V5/V6 (or comparable CAD software)
• Geometric Dimensioning & Tolerancing (GD&T)
• Design for Six Sigma (DFSS) methodologies
• CAE simulation analysis and interpretation
• Design for Manufacturing (DFM) and MoldFlow analysis
• Tooling design and injection‑trial coordination
• Plastics engineering principles for part layout and paint processes
• Supplier management and collaboration