Interior Design Engineer I at Tesla
INTERNSHIP & FULL-TIME
Non-Disclosure Agreement: I will only disclose non-proprietary information regarding my work at Tesla. All information and images are public knowledge.
Making Impact as an Intern
As a Vehicle Engineering intern at Tesla, I led the interior team in optimizing the cost analysis process for vehicle components, ensuring we received the most competitive pricing. To achieve this, I developed and leveraged a “should cost” template to systematically break down costs for complex systems, such as a center console, into granular detail. Using a bottom-up approach, I accurately estimated top level pricing by itemizing expenses like raw materials, raw materials processing, and assembly costs for each part. By providing data-driven justifications for estimates, I enabled the team to push back on supplier quotes and drive the awarded cost down.
Beyond sourcing support, I independently designed and developed a 12V cover assembly for the Model 3/Y center console, leveraging rapid prototyping to minimize development time. The final design maintained a premium feel while achieving a 67% cost reduction compared to the Model S concept, offering $12.5 million in savings over five years. It also reduced assembly complexity and eliminated the over-torquing associated with the prior design (see video).
Model S Concept
Additionally, I led DFM discussions for the aluminum decorative parts on the new Model 3/Y center console, using feedback to develop the design with other engineers on my team. This project involved designing around styling requirements from Studio, use and misuse requirements from craftsmanship, and limitations of combining aluminum working with back injecting.
Image 1: Aluminum Deco Parts
Driving Results in a Full-Time Role
As an Interior Design Engineer at Tesla, I led the development of a high-volume center console with 50+ injection-molded parts. I meticulously designed the components in Catia V5/V6, ensuring each met rigorous aesthetic and functional targets.
When I took ownership of the commodity in the middle of its design cycle, many changes and refinements still needed to be made. By reviewing Moldflow reports, I minimized molding defects such as sink, short shot, and warping and optimized tool design. I devised custom datum schemes to meet or, where possible, exceed craftsmanship gap and flush definitions. I leveraged rapid prototyping to identify issues before tooling was kicked off and improve the design development rate. To pass homologation requirements, I adhered to strict safety standards such as ECE-R21 to mitigate the severity of head impact in the event of a crash, proactively designed contingency plans for scenarios like vehicle roll-over, and safeguarded against the possibility of dual-occupant head contact via advanced CAE simulations. Finally, I led DFMEA workshops to discover failure modes proactively, conducted root cause analyses to understand the actual cause of issues, and oversaw tool production timelines to ensure program success through effective project management.
One of my more open-ended projects was developing a new substrate material, texture, and coating combination for a part that needed to be highly durable while maintaining an appealing visual appearance throughout the vehicle's life. To make a data-backed decision, I communicated with and collected pertinent information from raw material suppliers, T1 production suppliers, and our internal studio and materials teams. In the end, I set forth a series of tests for each promising combination, allowing me to build an apples-to-apples comparison decision matrix. I delivered my formal recommendation to key stakeholders and management using the matrix to back my decision.
Beyond design, I constructed part and assembly level “should cost” and mass assessments for internal tracking and supplier negotiations. Additionally, I have a proven ability to foster relationships with cross-functional teams and overseas vendors, as demonstrated by my successful collaborations with Tesla's global team and suppliers in Mexico and China.
Manager Feedback
Kenny Kobetsky - Managed Me Directly “ I really enjoyed managing Elliott Holdosh as both an intern and full-time Mechanical Engineer at Tesla these past 2+ years. He’s incredibly diligent, reliable, technically skilled, and a fast learner. Elliott made great design contributions to the new Center Console in the recent M3 refresh and much more. I highly recommend him for anyone searching for a super solid Mechanical Engineer! ”
Source: LinkedIn
Craig Cochrane - Managed Me Directly “ It is my pleasure to recommend Elliott Holdosh for a Mechanical Engineering focused role, especially in the automotive industry. ”
Internship:
“ Elliott showed he is a quick learner and prone to action. He never stagnated and always asked for more work (more than most interns I have managed). He juggled a lot of tasks in parallel and managed to meet expected deadlines for deliverables. For this reason, we proceeded to hire Elliott into a full time engineering role. ”
Full Time:
“ He was nearly reaching the next title level ‘mechanical design engineer’ with his expanded level of scope, knowledge, and collaboration by the end of his tenure at Tesla. ”
Source: Letter of Recommendation