What to Expect
Tesla is seeking a highly skilled and analytical Battery Cell Simulation Engineer to join our Battery Cell – Supplier Industrialization Engineering team. The ideal candidate will specialize in developing and applying multi-physics simulation models that bridge the gap between battery cell manufacturing processes and the resulting electrochemical, mechanical, and thermal failure modes. This role is critical in enabling predictive quality assurance, process optimization, and failure mitigation in next-generation battery cells. You will work at the intersection of materials science, manufacturing engineering, and computational modeling to identify process-induced defects (e.g., electrode misalignment, winding/stacking process variation, particle agglomeration, electrolyte distribution anomalies) and simulate their impact on cell performance, longevity, and safety.
What You'll Do
Develop and validate finite elements (FE), computational fluid dynamics (CFD), and electrochemical-thermal (EC-TH) simulation models to predict how manufacturing parameters (e.g., coating thickness, drying temperature, calendaring pressure, winding tension) influence internal cell architecture and degradation mechanisms
Establish digital twins of battery cell manufacturing processes (e.g., slurry mixing, coating, drying, calendaring, winding, stacking, electrolyte filling) to simulate process variability and its downstream effects on cell reliability
Correlate simulation results with experimental data from lab-scale and pilot-line production (e.g., X-ray CT, SEM, EIS, cycle testing, abuse testing) to refine models and improve predictive accuracy
Identify and model root causes of common failure modes such as lithium plating, internal short circuits, mechanical stress cracking, electrolyte dry-out, and capacity fade—tracing them back to specific process steps
Collaborate with process engineers, materials scientists, and test teams to translate simulation insights into actionable process improvements and quality control criteria
Lead the development of simulation-based design of experiments (DoE) frameworks to optimize manufacturing parameters while minimizing failure risk
What You'll Bring
Master’s or PhD in Mechanical Engineering, Materials Science, Chemical Engineering, Physics, or a related field, or equivalent experience
8+ years of experience in battery cell simulation or manufacturing process modeling (preferably in lithium-ion batteries)
Proficiency in simulation tools such as ANSYS, COMSOL Multiphysics, Abaqus, FEniCS, or OpenFOAM
Strong understanding of electrochemical reaction kinetics, solid-state diffusion, and thermal-mechanical behavior in battery cells
Experience with Multiphysics coupling (thermal-electrochemical-mechanical) modeling
Familiarity with battery cell manufacturing processes (coating, drying, calendaring, winding, sealing, electrolyte injection)
Strong programming skills in Python, MATLAB, or C++ for automation, post-processing, and model calibration
Demonstrated ability to interpret experimental data and use it to validate and refine simulation models
Compensation and Benefits
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
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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
Expected Compensation
$152,000 - $264,000/annual salary + cash and stock awards + benefits
Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.
Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws.
Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.
