Thermal / Mechanical Engineer – Integrated Rack Power Platform
About the role
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. 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.
Responsibilities
- Design the complete mechanical enclosure (1OU or 2OU shelf) using SolidWorks or Creo, including:
- Sheet metal chassis
- Busbar routing
- Internal structural supports
- External connector interfaces
- Solve the core thermal challenge of integrating:
- High-power semiconductors and magnetics operating at 100–125°C junction temperatures
- Solid-state battery cells requiring sub-45–60°C operating temperatures
- Directed airflow paths
- Temperature isolation zones
- Heat spreaders
- Fan selection
- Perform CFD thermal simulations using:
- Ansys Icepak
- FloTHERM
- SigmaET
- Optimize airflow under worst-case operating conditions including:
- Full electrical load
- 35–40°C inlet air (ASHRAE A1/A2)
- Fan degradation scenarios
- Design to OCP ORv3 mechanical specifications, including:
- Shelf width and depth
- Connector positioning
- Front-to-back airflow
- Ejector handle placement
- Guide rail interfaces
- Weight-per-OU limitations
- Develop hot-swap sled mechanisms featuring:
- Proper insertion/extraction force curves
- Blind-mate power connector alignment
- Guide rail compliance
- Tool-less serviceability
- Collaborate with Battery Systems Engineering on:
- Cell pack mounting
- Compression systems
- Thermal interface materials
- Mechanical isolation within the enclosure
- Perform vibration and shock analysis for:
- ISTA 3-Series shipping requirements
- Bellcore Zone 4 seismic requirements
- Lead Design for Manufacturing (DFM) activities with contract manufacturers, including:
- Tolerances
- Punching and stamping
- Spot welding
- Tolerance stack-up analysis
- Support UL 62368-1 mechanical and flammability requirements including:
- Material selection (94V-0)
- Component spacing
- Enclosure integrity
- Interface directly with hyperscaler mechanical integration teams throughout product qualification.
Requirements
8+ years designing thermal-mechanical enclosures for: Rack-mounted power systems, Compute platforms, Telecom equipment. Demonstrated expertise with CFD thermal simulation tools including: Ansys Icepak, FloTHERM, SigmaET. Proficiency with SolidWorks or Creo for detailed mechanical design. Extensive sheet metal design experience for high-volume manufacturing, including: Bend radii, Punching and stamping, Spot welding, Tolerance stack-up analysis. Proven track record taking products through contract manufacturing and thermal validation in production or hyperscale data center environments. Strong understanding of airflow management in forced-convection rack systems.
Qualifications
- Strong understanding of airflow management in forced-convection rack systems.
Skills
Direct experience with OCP Open Rack / ORv3 mechanical specifications. Experience with battery pack thermal management in: Electric vehicles, Stationary energy storage, Telecom backup systems. Exposure to liquid cooling or cold plate design for next-generation rack power shelves. Experience integrating blind-mate high-power connectors from manufacturers such as: Amphenol, TE Connectivity, Molex. Familiarity with: UL 62368-1 mechanical/flammability requirements, UL 1973 battery enclosure requirements. Knowledge of IP67 and NEMA ratings for edge or outdoor deployment variants. Experience with vibration and shock testing to: ISTA 3-Series, GR-63-CORE.
Benefits
Not specified.
Pay
Not specified.
Schedule
Not specified.