Sr. Test Engineer, Abuse Test & Engineering

We are seeking a highly motivated engineer to lead the evaluation and testing of battery propagation resistance across vehicle and energy storage programs. In this role, you will own the test process end-to-end—from design evaluation, test conception, planning, and execution, through to results analysis and collaboration on design decisions. You will also develop innovative test methods to investigate failure modes from a first-principles perspective and help define next-generation pack architectures. Your work will directly influence Tesla’s ability to rapidly launch and optimize cutting-edge products at scale.
What You’ll Do
· Lead battery propagation resistance efforts on assigned programs in close collaboration with the cell and pack design, test, and manufacturing teams
· Partner with internal teams to develop cell and pack designs that meet safety and abuse specifications
· Define and communicate test plans, resource requirements, and timelines for each program phase based on risk and schedule
· Present results and design recommendations to cross-functional stakeholders and executives
· Develop tests tailored to pack architectures (geometric, thermal, electrical) to study failure mode frequency, severity, and mechanisms
· Recommend new methods to deepen our understanding of failure modes
· Investigate failure modes and propose strategies to deepen organizational understanding
· Collaborate with technicians and test systems engineers to optimize tests, identifying opportunities for improved design, throughput, data fidelity, and integrity
· Enhance statistical frameworks, results databases, and visualization tools for more robust decision-making
· Design test setups and instrumentation to improve model validation, accuracy, and utility
What You’ll Bring
· Bachelor’s Degree in Mechanical, Electrical, or Chemical Engineering, or equivalent experience
· 2+ years’ experience in physically applied-engineering (lab, machine shop, hobby project, etc.)
· Strong problem-solving ability using first principles, with a foundation in heat transfer and electrical engineering fundamentals
· Hands-on experience with fabrication, modification, instrumentation, troubleshooting, and inspection
· Proficiency with instrumentation and data acquisition systems
· Strong collaboration and leadership skills; comfortable guiding cross-functional teams and technicians
· Ability to plan and execute multiple concurrent activities in a fast-paced, rapidly evolving environment
· Experience with Matlab or Python
· Proficiency in CAD for fixture or test design
· Knowledge of SQL or database management
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