Thermal / Mechanical Engineer – Integrated Rack Power Platform

Thermal / Mechanical Engineer – Integrated Rack Power Platform Location: San Jose, CA (On-site)Reports To: Head of Engineering, Data Center 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. 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. What You'll DoDesign the complete mechanical enclosure (1OU or 2OU shelf) using SolidWorks or Creo, including:Sheet metal chassisBusbar routingInternal structural supportsExternal connector interfacesSolve the core thermal challenge of integrating:High-power semiconductors and magnetics operating at 100–125°C junction temperaturesSolid-state battery cells requiring sub-45–60°C operating temperaturesDirected airflow pathsThermal isolation zonesHeat spreadersFan selectionPerform CFD thermal simulations using:Ansys IcepakFloTHERM6SigmaETOptimize airflow under worst-case operating conditions including:Full electrical load35–40°C inlet air (ASHRAE A1/A2)Fan degradation scenariosDesign to OCP ORv3 mechanical specifications, including:Shelf width and depthConnector positioningFront-to-back airflowEjector handle placementGuide rail interfacesWeight-per-OU limitationsDevelop hot-swap sled mechanisms featuring:Proper insertion/extraction force curvesBlind-mate power connector alignmentGuide rail complianceTool-less serviceabilityCollaborate with Battery Systems Engineering on:Cell pack mountingCompression systemsThermal interface materialsMechanical isolation within the enclosurePerform vibration and shock analysis for:ISTA 3-Series shipping requirementsGR-63-CORE (Bellcore Zone 4) seismic requirementsLead Design for Manufacturing (DFM) activities with contract manufacturers, including:TolerancesToolingBend radiiSpot weldingPEM fastener insertionAssembly sequence optimizationSupport UL 62368-1 mechanical and flammability requirements including:Material selection (94V-0)Component spacingEnclosure integrityInterface directly with hyperscaler mechanical integration teams throughout product qualification.What You BringRequired Qualifications8+ years designing thermal-mechanical enclosures for:Rack-mounted power systemsCompute platformsTelecom equipmentDemonstrated expertise with CFD thermal simulation tools including:Ansys IcepakFloTHERM6SigmaETProficiency with SolidWorks or Creo for detailed mechanical design.Extensive sheet metal design experience for high-volume manufacturing, including:Bend radiiPunching and stampingSpot weldingTolerance stack-up analysisProven 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.Preferred QualificationsDirect experience with OCP Open Rack / ORv3 mechanical specifications.Experience with battery pack thermal management in:Electric vehiclesStationary energy storageTelecom backup systemsExposure to liquid cooling or cold plate design for next-generation rack power shelves.Experience integrating blind-mate high-power connectors from manufacturers such as:AmphenolTE ConnectivityMolexFamiliarity with:UL 62368-1 mechanical/flammability requirementsUL 1973 battery enclosure requirementsKnowledge of IP67 and NEMA ratings for edge or outdoor deployment variants.Experience with vibration and shock testing to:ISTA 3-SeriesGR-63-COREWhy This Role Matters 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. 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. 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.