Principal Mechanical/Thermal Engineer (AI/Startup) – Silicon Valley

Our premier Silicon Valley AI startup client is hiring a Principal Mechanical/Thermal Engineer to lead the hardware definition of their next-generation AI infrastructure. This is a high-impact leadership role where you will serve as the primary technical authority for the physical architecture of advanced server platforms. This role will bridge the critical gap between ultra-high-power silicon packaging, liquid-cooled node design, and massive-scale Rack deployments.

Responsibilities:

• Lead the end-to-end mechanical definition of server blades, high-density chassis, and rack-level enclosures.
• Architect the integration of sliding rails, blind-mate connectors, precision standoffs, and high-load Extraction Handles.
• Define mechanical paths for ultra-high-density power delivery (Busbars) and complex cable management.
• Direct the design of Liquid Cooling Cold Plates, optimizing internal micro-channels and manifold fluid distribution.
• Validate the selection and integration of Quick Disconnects (QDs) and leak-mitigation systems.
• Drive thermal strategy for 1kW+ nodes using CFD to balance hybrid air/liquid cooling.
• Optimize designs for high-volume manufacturing using Precision Milling, Die Casting, and Complex Sheet Metal fabrication.
• Ensure system integrity against Transportation Shock & Vibration and extreme Thermal/Humidity cycling.
• Implement Design for Cost (DfC) and Easy Assembly (DFA) to ensure seamless serviceability and global deployment.

Requirements:

• B.S. or M.S. in Mechanical Engineering.
• 12+ years in high-performance compute (HPC), AI hardware, or datacenter systems.
• A proven track record of owning at least one full product lifecycle—from blank-page concept through High-Volume Manufacturing (HVM).
• Deep technical knowledge of fluid dynamics, wetted material compatibility, and the mechanical nuances of “Drip-Free” connector integration.
• Expert-level understanding of metal fabrication (Milling, Casting, Sheet Metal) and how these processes impact thermal performance and structural integrity.
• Expert user of CFD and FEA tools for structural and vibration analysis.
• Ability to drive technical alignment across silicon, power, and optical engineering teams.

Relocation and Visa Requirements:

• Strongly prefer candidates that reside in the San Francisco Bay Area/Silicon Valley Area.
• Will provide relocation assistance to the right candidate (that resides in the United States).
• Will transfer H1-B Visa to candidates (that resides in the United States).
• All candidates MUST reside in the United States.

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