Robotics Mechanical Design Engineer, Force Torque Sensing, Optimus

Description

Tesla's actuator team designs and builds the rotary and linear electromechanical actuators for Optimus, our humanoid bi-pedal robot. The team brings together mechanical, electrical, and electromagnetic engineers in a highly collaborative environment. As our Force/Torque Sensing specialist, you will own how Optimus measures the forces and torques at its joints and limbs. That sensing makes precise, safe, and dexterous motion control possible. You will work with motor design, gear system, controls, and firmware engineers to design, integrate, and validate sensing solutions that are accurate, compact, robust, and manufacturable at scale. You will also support industrialization and production, helping to turn prototype sensors into high-volume, low-cost, reliable hardware. 

Responsibilities

• Design and integrate force and torque sensing into rotary and linear actuators, including joint torque sensors, load cells, and multi-axis force/torque sensors for Optimus limbs, hands, and feet 
• Develop sensing architectures (strain gauge, magnetic, capacitive, optical, and elastic-element-based) that balance accuracy, bandwidth, stiffness, size, cost, and reliability
• Work with motor, gearbox, and actuator designers to embed sensors in the mechanical design with minimal impact on torque density, efficiency, and packaging
• Partner with controls, firmware, and electrical engineers on signal conditioning, analog front ends, calibration, filtering, and sensor fusion to deliver clean, low-latency torque and force feedback
• Analyze and mitigate error sources such as temperature drift, hysteresis, crosstalk, creep, overload, and EMI
• Build calibration fixtures and test benches to characterize sensor performance, including accuracy, linearity, repeatability, fatigue, and thermal behavior, in actuators and at the full-robot level
• Design, build, and test sensor and actuator prototypes, including basic fabrication, machining, wiring, electronics debugging, and parts chasing
• Continuously evaluate new sensing technologies and design improvements to reduce cost and increase robustness and performance
• Collaborate with supply chain, vendors, and manufacturing engineers to industrialize sensors, including end-of-line calibration and test strategies
• Support root-cause analysis and design iteration using field and validation data 

Requirements

• Degree in Mechanical Engineering, or a related field, or equivalent experience
• 3+ years of experience designing and integrating force and torque sensing for electromechanical actuators, robotics, or motion control applications
• Hands-on experience with sensing technologies such as strain gauges, load cells, magnetic or optical encoders, and elastic-element torque sensors
• Strong understanding of instrumentation, including bridge circuits, amplification, ADCs, noise analysis, and calibration methods
• Experience with structural and mechanical analysis (FEA, stiffness, stress, and fatigue) to design flexures and sensing elements
• Familiarity with geared actuator systems (planetary, strain wave, cycloidal, ball screw, or lead screw) and how drivetrain design affects sensing
• Demonstrated success in a product design and manufacturing environment, from prototype through production
• Ability to build and debug test setups and prototypes, including data acquisition, scripting (e.g., Python or MATLAB), and data analysis
• Familiarity with electric motors, drives, and motion control, including force/torque control and compliance
• Experience in Ansys, NASTRAN a plus 

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
• 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
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)

Expected Compensation

$108,000 - $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.