Thermal Process Engineer

Company Overview
We are a high-growth startup building next-generation high‑performance switching systems for hyperscale and AI data centers. Our platforms power large-scale cloud infrastructure, GPU clusters, and high-density compute environments where performance, reliability, and thermal efficiency are critical to customer operations.
Position Summary
The Liquid Cooling Process Engineer owns the manufacturing process definition, validation, and scaling of liquid-cooled network products in conjunction with NH engineering. This role bridges thermal design, mechanical design, manufacturing engineering, reliability, and supply chain to ensure liquid-cooling solutions—cold plates, manifolds, hoses, quick-disconnects, and TIMs—are repeatable, leak-free, thermally efficient, and production-scalable.
The role is critical to enabling >50–100 kW per rack architectures, supporting next-generation AI fabrics and ultra-high-bandwidth network switches without compromising reliability or serviceability.
Key Responsibilities
Process Definition & Development
Define end-to-end manufacturing processes in close collaboration with engineering for:
Direct-to-chip cold plates
Manifolds and distribution plates
Tubing, hoses, and quick-disconnects (QDs)
TIM application (grease, PCM, gap fillers)
Develop process flow diagrams, control plans, and work instructions
Ensure processes are DFM/DFA/DFS compliant and serviceable in field environments
NPI Execution (EVT → DVT → PVT → MP)
Enable fast prototyping and rapid iterative development cycles
Drive development of DFMEA (Design Failure Mode Effects and Analysis) with engineering
Support thermal hardware from early EVT through HVM ramp
Identify and mitigate process risks:
Leak paths
Torque variation
Flatness and coplanarity
Particulate contamination
Lead process validation builds and golden line definition
Partner with ODMs to ensure manufacturability at scale
Assembly, Tooling & Automation
Specify and qualify:
Torque tools and sequencing strategies
Dispensing systems for TIMs and sealants
Pressure and leak-test equipment (air, helium, liquid)
Drive semi-automated and automated solutions for:
Cold-plate installation
Hose routing and retention
QD (Quick Disconnect) engagement verification
Define poka-yoke mechanisms to prevent mis-builds
Quality, Reliability & Validation
Own PFMEA (Process Failure Mode Effects and Analysis) and control plans for liquid-cooling processes
Define acceptance criteria for:
Leak rate
Pressure decay
Flow resistance
Thermal performance
Support HALT/HASS, thermal cycling, vibration, and shock testing
Lead root-cause analysis for field and factory issues (leaks, clogging, corrosion)
Data, Monitoring & Continuous Improvement
Establish process KPIs:
Leak ppm
Torque Cp/Cpk
TIM thickness uniformity
Yield and rework rates
Integrate test data into MES and quality dashboards
Drive yield improvement and cost reduction through data-driven analysis
Supplier & Partner Management
Work closely with:
Cold-plate suppliers
Hose and QD vendors
TIM and sealant suppliers
ODM/OEM manufacturing teams
Qualify suppliers and define incoming quality requirements
Support dual-sourcing and cost-down initiatives
Required Qualifications
Master’s degree in Mechanical Engineering, Manufacturing Engineering, or related field
7+ years experience in manufacturing and process engineering with 2+ years of liquid cooling experience
Hands-on experience with thermal or fluid-handling hardware
Strong understanding of:
Mechanical tolerances and torque control
Assembly processes and tooling
Manufacturing quality systems
Thermodynamics
Heat transfer
Experience with liquid-cooled servers, network switches, or HPC systems
Experience working in or with startups

Employment type
Full-Time

Work arrangement
No