Gen 3 Wall Connector Tester

The Problem

Tesla's Gen 3 Wall Connector was racing toward a global market release with end-of-line validation still ad hoc. Without a deterministic test bench, latent electrical, firmware, and ingress failures could slip into customer hands at scale — and a single field failure on a 240V product is a recall waiting to happen.

The Approach

Architected an end-to-end automated pneumatic test system, spanning mechanical design, electronic test protocols, and SWC (Single-Wire CAN) debugging. Owned the mechanical side singlehandedly — CAD, drawings, supplier management, prototyping — while curating Resistance, Hipot, Insulation, Functional, Zero Current Burn-In, Leak, UHF, WiFi/NFC, and Energy Metering calibration routines into one validation suite.

The Outcome

The $140K test system became a cornerstone of Gen 3 Wall Connector production validation. Critical flaws were identified before the China market release, and the bench now serves as the deterministic gate every unit passes before it leaves the line.