Thermal Design Intern

Job Description

About Tesla Energy Thermal Design Team

The Tesla Energy thermal design team is a close-knit group of hands-on mechanical engineers dedicated to advancing battery, charging, and renewable technologies. Their mission is to facilitate a renewable energy ecosystem and redefine future energy usage. As part of this team, interns will be involved in designing and packaging the thermal systems critical to Tesla Energy products’ success. The role requires significant collaboration with various internal teams including architecture, adjacent design, manufacturing, and service, emphasizing the application of engineering fundamentals to create thermal assemblies that are core to Tesla’s achievements. The team is characterized by individuals who are fast-moving, self-motivated, resilient, problem-solvers, and strong team players.

About the Internship Program

The Internship Recruiting Team at Tesla is passionate about recognizing and developing emerging talent. This is a year-round program that places students in positions designed for technical, professional, and personal growth. Interns work closely with their manager, mentor, and team, gaining an experience that allows them to truly experience life at Tesla. Interns are included in projects that are critical to their team’s success.

Job Description

Position Details:
• Start Date: Expected to start August/September 2025.
• Duration: Continues through the entire Fall term (approx. December 2025) or potentially into Winter/Spring 2026 if available. A minimum commitment of 12 weeks is required for most internships.
• Work Arrangement: Full-time and on-site.
• International Students (CPT): Must consult their school regarding the ability to work 40 hours per week on-site, as many may be limited to part-time during the academic year.

Location:
• Palo Alto, CA

What You’ll Do (Responsibilities):
• Take component or system design responsibility from initial concept through production launch and ramp-up.
• Perform thermal / fluid reduced order modeling and feasibility studies to guide mechanical designs.
• Develop and execute component/subsystem design validation plans and test methods to ensure product adherence to requirements.
• Engage in hands-on engineering prototype builds and component fabrication.
• Advance product performance while optimizing for efficiency, cost, manufacturability, and serviceability.
• Define specifications (dimensional, functional, performance, manufacturing).
• Create high-quality drawing packages and manufacturing instructions for parts and assemblies.
• Collaborate with systems, electrical, supply chain, manufacturing, service/deployment, and reliability teams to transition designs from prototyping to mass production.
• Root cause and solve test failures and production problems.
• Drive relentless improvement of existing products.
• Undertake component and system integration design, covering areas like fan/heat exchanger assemblies, vapor compression cycles, and coolant systems.

What You’ll Bring (Qualifications/Skills):
• Education: Currently pursuing a Degree in Mechanical Engineering or a related field.
• Work Ethic: A strong desire to own a lot and work hard (due to small teams and fast timelines).
• Design & Prototyping: Demonstrated ability or ability to learn to create products, from CAD design to hands-on prototyping.
• Attention to Detail: A detail-oriented personality with solid documentation and reporting skills.
• Engineering Fundamentals:
• Strong fundamentals in heat transfer, fluids, mechanics, and electronics.
• Basic understanding of electrical design fundamentals.
• Basic understanding of material science of components used in mechanical design (metals, insulators, plastics, connectors, gaskets, etc.).
• Technical Tools & Software:
• Thermal analysis and CFD experience.
• Experience with CATIA V5 or V6.
• Working knowledge of Matlab or Python.
• Preferred Experience (A Plus):
• Experience with student engineering projects such as Formula Vehicle, Solar Car, or Hyperloop.
• Direct machine shop skills.
• Knowledge of GD&T, finite element analysis, and design for reliability concepts.

Benefits:
As a full-time Tesla Intern, you will be eligible for a comprehensive benefits package, including:
• Medical Plans: Aetna PPO and HSA plans with two options, including a $0 payroll deduction option.
• Family Benefits: Family-building, fertility, adoption, and surrogacy benefits.
• Dental & Vision: Dental (including orthodontic coverage) and vision plans, both with a $0 payroll contribution option.
• Health Savings Account (HSA): Company Paid HSA Contribution when enrolled in the High Deductible Medical Plan with HSA.
• Flexible Spending Accounts (FSA): Healthcare and Dependent Care Flexible Spending Accounts.
• Financial Benefits: 401(k), Employee Stock Purchase Plans, and other financial benefits.
• Insurance: Company Paid Basic Life, AD&D, and short-term disability insurance.
• Support Programs: Employee Assistance Program.
• Time Off: Sick time after 90 days of employment and Paid Holidays.
• Childcare Support: Back-up childcare and parenting support resources.
• Voluntary Benefits: Critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance.
• Commuter Benefits.
• Employee Discounts and Perks Program.

Expected Compensation:
• Hourly Rate: $20.00 – $50.00/hour, plus benefits.
• Variability: Pay may vary based on individualized factors such as market location, job-related knowledge, skills, and experience. The total compensation package may also include other elements dependent on the specific position offered.