Thermoform Design Engineer (Tesla

Thin-Gauge Thermoform Design Engineer (Tesla, U.S.): This role focuses on designingthin-gauge thermoformed plastic components (e.g. lightweight trays, enclosures, packaging inserts) for Tesla's products and operations. The engineer leadsend-to-end design of thermoformed parts and tooling from concept through production, ensuringdesign for manufacturability in thin plastic sheet forming (typically<1.5 mm thickness). Responsibilities include creating detailed3D CAD models and drawings, conductingfeasibility and tolerance analyses to optimize designs, and collaborating cross-functionally with manufacturing, quality, and supply chain teams to meethigh-volume production and quality standards. The engineer also supportstooling fabrication and validation with internal teams or external toolmakers to ensure that thermoforming molds and processes achieve the required performance and precision. (Notably, Tesla's hiring managers have indicated flexibility for these specialized roles, even considering remote work arrangements.) This is ahands-on design position requiring technical expertise inthin-gauge thermoforming processes, creativity in problem-solving, and strong coordination skills.

Required Skills/Qualifications:A solid foundation in mechanical design and specific experience with thin-gauge thermoforming is essential. Key requirements typically include:

·Education & Experience: AB.S. in Mechanical Engineering or a related field (e.g. Manufacturing or Industrial Design) and3+ years of experience designingthermoformed plastic products and tooling – particularly in thin-gauge applications (e.g. packaging or lightweight enclosures).

·CAD Proficiency: Advanced skill in3D CAD software (such asSolidWorks, CATIA, or equivalent) for complex part modeling, assembly design, and detailed drawing creation.

·Thermoforming Process Knowledge:Strong understanding of thin-gauge thermoforming processes, including vacuum forming and pressure forming techniques. Familiarity withthermoplastic materials commonly used in thin-gauge thermoforming (e.g.ABS, HIPS, PETG, PVC) and how they behave under heat and vacuum is critical.

·Tooling & DFM Skills: Experience indesigning thermoforming molds/tooling andcollaborating with toolmakers or machine shops for fabrication and validation of those tools. Ability to optimize part designs for manufacturability, trimming, and high-volume production (DFM) is required.

·Analytical & Quality Focus: Competence intolerance analysis, material thickness optimization, and part feasibility studiesfor thin-gauge parts. Strong attention to detail withquality control considerations for plastic part integrity and consistency.

·Collaboration & Communication: Ability towork with cross-functional teams (design engineering, manufacturing, quality, supply chain) to refine requirements and ensure successful integration of thermoformed components into the overall system. Excellent communication skills are essential for bridging design with production.

Preferred Skills/Pluses:Candidates with the following are oftenpreferred in thin-gauge thermoforming roles, per industry and Tesla's practices:

·Industry Exposure: Prior experience in anautomotive or high-volume manufacturing environment, especially involvingpackaging engineering or plastic component design, is a strong plus (demonstrates ability to meet rigorous performance and quality standards at scale).

·Advanced Manufacturing Knowledge: Familiarity withlean/automated manufacturing processes andrelated plastic forming methods (e.g. heavy-gauge thermoforming orinjection molding) is beneficial to broaden problem-solving approaches in design.

·Simulation & Analysis: Experience withCAE/FEA tools for simulating thermoformed part behavior ordesign optimization can be advantageous, enabling better prediction of material performance (e.g. shrinkage, wall thinning).

·Standards & Compliance: Knowledge ofindustry standards and testing protocols relevant to thin-gauge plastics (such aspackaging standards or automotive component requirements) is helpful, especially if the role involves ensuring designs meet safety, durability, or regulatory criteria.

Overall,Tesla's thin-gauge thermoform design engineers are expected to combinemechanical design expertise, deepthermoplastics know-how, andpractical manufacturing insight to deliver innovative lightweight plastic solutions that meet Tesla's quality and volume production needs.

Thank you