R AYYA N S A P PAYA N I
Mechanical Design Engineer
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Robotics & Autonomous Systems
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CAD & FEA Specialist
Fremont, California, United States
linkedin.com/in/rayyan-sappayani
Tesla Hiring Team
Tesla Engineering
Palo Alto, California, United States
Dear Tesla Hiring Team,
Please consider me for the Mechanical Engineer opportunity. I am including my resume that lists my qualifications and experience.
With hands-on experience in mechanical design engineering for autonomous systems, I specialize in developing robust mechanical
solutions for cutting-edge robotics platforms. My work at Shield AI involved designing and optimizing mechanical systems for
unmanned aerial vehicles, where I translated complex performance requirements into practical, manufacturable designs that operate
reliably in demanding environments.
I reviewed the requirements of the job opening and I believe my candidacy is an excellent fit for this position. Some of the key
requirements that I have extensive experience with include:
Mechanical design and analysis of complex assemblies using SolidWorks and other CAD platforms
Structural and thermal FEA simulation to validate designs and optimize performance
Design for manufacturing (DFM) and design for assembly (DFA) principles applied to aerospace and robotics components
Materials selection and testing for lightweight, high-strength applications in autonomous systems
Cross-functional collaboration with electrical, software, and systems engineering teams to integrate mechanical solutions
Rapid prototyping and iterative design validation using 3D printing, CNC machining, and conventional fabrication methods
Python scripting for design automation, simulation preprocessing, and data analysis
GD&T application and tolerance stack-up analysis for precision assemblies
My experience at Shield AI as a Mechanical Design Engineer, combined with my internship at the Center of Space Sciences at UT-
Dallas, gives me a unique perspective on how mechanical engineering enables breakthrough capabilities in autonomous and
aerospace systems. I understand the importance of rigorous analysis, lightweight design, and manufacturability—principles that
directly align with Tesla's approach to engineering excellence in electric vehicles and autonomous technologies.
My experience spans the full product development lifecycle, from initial concept generation through detailed design, prototyping,
testing, and production handoff. At Shield AI, I contributed to the mechanical architecture of autonomous aircraft systems, working
within multidisciplinary teams to ensure mechanical designs met stringent weight, reliability, and performance requirements. I
developed proficiency in SolidWorks for complex surfacing and assembly modeling, and I applied my Python skills to automate
repetitive design tasks and analyze test data. My internship at the Center of Space Sciences involved hands-on research and fabrication
in a university laboratory setting, where I gained experience with precision instrumentation and satellite subsystem design.
I am particularly drawn to Tesla's commitment to accelerating the world's transition to sustainable energy and transportation. The
opportunity to apply my mechanical engineering expertise to Tesla's vehicle and energy products—where innovation, manufacturing
scale, and product reliability intersect—represents an ideal next step in my career. My ability to thrive in fast-paced technical
environments, combined with my foundation in robotics, autonomous systems, and advanced manufacturing, positions me to
contribute meaningfully to Tesla's engineering teams.
Thank you in advance for taking the time to read my cover letter and to review my resume.
Rayyan Sappayani - Cover Letter
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