Tesla · 2 days ago
CAE Engineer, Optimus Gears
Palo Alto, California
Full-time
Onsite
Mid, Senior Level
$108K/yr - $258K/yrTesla is a leading company in the robotics sector, focusing on the development of humanoid bi-pedal robots. As a CAE Engineer, you will be responsible for guiding the structural design of gears and gear assemblies, collaborating with various teams to analyze and optimize designs, and pioneering efficient engineering approaches for the Optimus robot.
AutomotiveElectric VehicleEnergyManufacturingRenewable EnergyTransportation
Responsibilities
Conduct Loaded Tooth Contact Analysis (LTCA) to predict contact patterns, transmission error (TE), and contact stresses under peak torque and duty-cycle loads
Define and optimize gear micro-geometry corrections (crowning, tip/root relief, twist) to compensate for system deflections and minimize gear whine and rattle
Integrate flexible housing and shaft FEA models into drivetrain simulation environments to accurately predict misalignment at the gear mesh
Move beyond component-level analysis to perform full system-level simulations, accounting for housing flexibility, shaft deflection, and thermal effects to balance durability requirements with NVH targets
Collaborate with Test Engineering to design experiments and validate simulation models against physical dyno data, tuning models based on contact pattern mark-outs and NVH measurements
Partner with Design Engineers to iterate on macro-geometry parameters (module, pressure angle, helix angle) to achieve optimal power density and provide data-driven product guidance
Establish and maintain modeling standards, methods, and best practices for current and future programs
Qualification
Required
Degree in Mechanical Engineering or related field, or equivalent experience
Strong foundation in Engineering Mechanics, Computational Mechanics, Material Science, and Finite Element Theory and applications
Demonstrated ability to guide Gears and Gear Train designs through CAE, from concept to mass production, across robotics, automotive, or relevant industries
Expertise in building high-fidelity FE models at component, sub-system, and full-system levels
Proficiency in linear and non-linear static, dynamic and modal simulations and experience developing multi-physics simulation workflows (e.g., thermal-mechanical, mechanical-electrical)
Advanced knowledge in material characterization and modeling, including nonlinear elasticity, viscoelasticity, creep, and strain-rate dependent plasticity in Metals, Plastics, Polymers and Adhesives
Proficiency in CAE Tools such as BETA CAE, LS-DYNA, Abaqus, ADAMS, COMSOL, OPTISTRUCT, Design Life, FE Safe, ROMAX, MASTA, etc
Strong programming and data analysis skills in MATLAB, Python, or equivalent
Excellent communication and interpersonal skills with the ability to collaborate effectively across cross-functional teams
Benefits
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
Company
Tesla
Tesla is an electric vehicle and clean energy company that provides electric cars, solar, and renewable energy solutions.
Founded in 2003
10001+ employees
H1B Sponsorship
Tesla has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
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2025 (2796)
2024 (2113)
2023 (1304)
2022 (1227)
2021 (1102)
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Funding
Current Stage
Public CompanyTotal Funding
$20.12BKey Investors
Societe GeneraleEuropean UnionPennDOT
2024-10-05Post Ipo Debt· $783M
2023-09-13Grant· $159.6M
2023-08-15Grant· $0.23M
Leadership Team
Vaibhav Taneja
Chief Financial Officer
Tom Zhu
SVP of Automotive
Recent News
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