Lead Failure Analysis Engineer, Mechanical / Mechatronics (m/w/d) Berlin, Germany

What to Expect

We are looking for a Failure Analysis Engineer to lead the failure analysis team in Berlin (Tesla Engineering Germany). This is the team lead. The electrical failure analysis engineer and the failure analysis technician report to you. The team finds root cause and contributing factors, so Tesla can reduce field, production, and development issues. You work with design, manufacturing, quality, and other engineering teams, across vehicle and energy products, including current models and products still in development. The role is hands-on. You own electromechanical failure analysis yourself, and you run the lab. You confirm and recreate failures, lead teardowns, and use optical microscopy, X-ray, and mechanical sample preparation to identify failure mechanisms. You report root cause and propose countermeasures with Design, Manufacturing, Quality, and the other failure analysis engineers. The right person has several years of industry experience, is comfortable taking assemblies apart and putting them back together, and can connect what they see under a microscope or on an X-ray to how the part was designed and built. A materials science background is preferred.?

What You’ll Do

• Lead the failure analysis team and laboratory. Manage operations, lab workflows, equipment, and the two people who report to you: the electrical failure analysis engineer and the failure analysis technician.
• Drive failure analysis of electromechanical assemblies from the first report through root cause and countermeasure, including failure confirmation, recreation, and teardown inspection.
• Use optical microscopes, 2D X-ray, and related inspection tools to characterize defects in mechanical and electromechanical hardware.
• Prepare mechanical samples (sectioning, grinding, polishing) so failure interfaces can be inspected, and document what you find.
• Disassemble and reassemble electromechanical assemblies while keeping the original form and function.
• Design and run experiments to test a hypothesis, either yourself or with the technician.
• Document inspections, replication tests, and teardowns in written reports, images, and the project tracking system.
• Work with Design, Manufacturing, Quality, and suppliers on containment and corrective action.
• Bring prior failure experience into design reviews and DFMEAs.?

What You’ll Bring

• Bachelor's or Master's degree in Mechanical Engineering, Mechatronics, Materials Science, or equivalent experience. A materials science background is preferred.
• 3-5 years of industry experience in failure analysis, reliability, product development, or a related hands-on engineering role. This is not a new-graduate role.
• Hands-on experience with optical microscopes, X-ray inspection, and teardown of mechanical or electromechanical assemblies.
• Able to take an assembly down to its subcomponents and explain what the parts are and how they work.
• Able to fully disassemble and reassemble electromechanical assemblies without losing function or form.
• Experience with mechanical sample preparation (saws, grinders, polishers) and with clear documentation: photos, optical images, and written reports.
• Strong written and spoken English. Able to explain a failure mechanism clearly to design and manufacturing stakeholders.
• Self-driven, structured, and comfortable in a fast-paced lab.
• Preferred: tensile test, pressure or leak test, machine shop equipment, CAN or LIN, and oscilloscope.

Tesla is an Equal Opportunity / Aff…? 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.

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