Thermal / Mechanical Engineer - Integrated Rack Power Platform
Job Description
Thermal / Mechanical Engineer – Integrated Rack Power Platform
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Location: San Jose, CA (On-site)
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Reports To: Head of Engineering, Data Center Power Platform
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About the Role
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We are building an integrated PSU + BBU rack power shelf that combines power conversion and solid-state battery backup into a single high-density platform for hyperscale AI data centers.
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This shelf must conform to OCP Open Rack / ORv3 mechanical specifications, manage two thermally incompatible subsystems within a shared enclosure, and pass hyperscaler qualification—where mechanical and thermal design are just as critical as electrical performance.
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As the Thermal / Mechanical Engineer, you will own the complete physical design of the product. You will translate circuit boards and battery packs into a manufacturable shelf that fits industry-standard racks, survives demanding data center environments, and can be serviced by a technician in seconds.
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What You'll Do
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Design the complete mechanical enclosure (1OU or 2OU shelf) using SolidWorks or Creo, including:
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Sheet metal chassis
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Busbar routing
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Internal structural supports
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External connector interfaces
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Solve the core thermal challenge of integrating:
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High-power semiconductors and magnetics operating at 100–125°C junction temperatures
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Solid-state battery cells requiring sub-45–60°C operating temperatures
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Directed airflow paths
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Thermal isolation zones
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Heat spreaders
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Fan selection
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Perform CFD thermal simulations using:
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Ansys Icepak
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FloTHERM
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6SigmaET
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Optimize airflow under worst-case operating conditions including:
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Full electrical load
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35–40°C inlet air (ASHRAE A1/A2)
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Fan degradation scenarios
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Design to OCP ORv3 mechanical specifications, including:
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Shelf width and depth
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Connector positioning
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Front-to-back airflow
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Ejector handle placement
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Guide rail interfaces
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Weight-per-OU limitations
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Develop hot-swap sled mechanisms featuring:
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Proper insertion/extraction force curves
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Blind-mate power connector alignment
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Guide rail compliance
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Tool-less serviceability
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Collaborate with Battery Systems Engineering on:
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Cell pack mounting
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Compression systems
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Thermal interface materials
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Mechanical isolation within the enclosure
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Perform vibration and shock analysis for:
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ISTA 3-Series shipping requirements
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GR-63-CORE (Bellcore Zone 4) seismic requirements
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Lead Design for Manufacturing (DFM) activities with contract manufacturers, including:
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Tolerances
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Tooling
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Bend radii
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Spot welding
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PEM fastener insertion
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Assembly sequence optimization
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Support UL 62368-1 mechanical and flammability requirements including:
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Material selection (94V-0)
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Component spacing
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Enclosure integrity
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Interface directly with hyperscaler mechanical integration teams throughout product qualification.
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What You Bring
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Required Qualifications
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8+ years designing thermal-mechanical enclosures for:
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Rack-mounted power systems
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Compute platforms
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Telecom equipment
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Demonstrated expertise with CFD thermal simulation tools including:
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Ansys Icepak
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FloTHERM
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6SigmaET
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Proficiency with SolidWorks or Creo for detailed mechanical design.
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Extensive sheet metal design experience for high-volume manufacturing, including:
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Bend radii
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Punching and stamping
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Spot welding
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Tolerance stack-up analysis
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Proven track record taking products through contract manufacturing and thermal validation in production or hyperscale data center environments.
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Strong understanding of airflow management in forced-convection rack systems.
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Qualifications
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Direct experience with OCP Open Rack / ORv3 mechanical specifications.
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Experience with battery pack thermal management in:
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Electric vehicles
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Stationary energy storage
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Telecom backup systems
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Exposure to liquid cooling or cold plate design for next- rack power shelves.
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Experience integrating blind-mate high-power connectors from manufacturers such as:
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Amphenol
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TE Connectivity
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Molex
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Familiarity with:
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UL 62368-1 mechanical/flammability requirements
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UL 1973 battery enclosure requirements
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Knowledge of IP67 and NEMA ratings for edge or outdoor deployment variants.
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Experience with vibration and shock testing to:
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ISTA 3-Series
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GR-63-CORE
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Why This Role Matters
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Hyperscalers do not negotiate on rack geometry. If the shelf does not fit, does not cool effectively, or cannot be serviced in seconds, it will never be evaluated—regardless of how strong the electrical design is.
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You will serve as the company's primary mechanical interface with hyperscaler qualification teams. Your understanding of both published and practical mechanical integration requirements can shorten qualification timelines by months.
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In a product where high-power electronics and solid-state battery cells share the same enclosure, you are the engineer responsible for making that coexistence physically possible.