Thermal Engineer – Testing, Validation & Failure Analysis

ENVICOOL; Fremont (CA); On-site; USD 95,000 - 130,000; Full time

Job summary

Envicool is actively seeking a hands-on Thermal Engineer to support testing, validation, failure analysis, and continuous improvement of liquid cooling products and thermal systems for high-power electronics and data centers.

The role requires a strong foundation in heat transfer, fluid mechanics, and thermodynamics, plus hands-on lab experience and the ability to translate data into practical engineering recommendations. On-site work in Fremont, CA, with collaboration across engineering teams.

Qualifications

• Have a Master’s or higher in Mechanical/Thermal Engineering or related field.
• Hands-on experience with thermal testing, instrumentation, and system validation.
• Experience with failure analysis, reliability, and quality improvement is preferred.
• Strong foundation in heat transfer, fluid mechanics, and thermodynamics.

Responsibilities

• Support design, build, and validation of liquid cooling solutions (cold plates, CDUs, system-level architectures).
• Set up test rigs and run thermal and fluid tests (temperature, flow, pressure, power, leaks).
• Conduct failure analysis on components and systems and identify root causes.
• Develop SOPs, validation protocols, and data analysis templates.
• Collaborate with engineering, manufacturing, quality, and suppliers to improve reliability.
• Assist with customer field failures and investigations.

Skills

Thermal engineering

Lab testing

Data analysis

Root cause analysis

Problem solving

Fluent English

Education

Master's degree or above in Mechanical Engineering or Thermal Engineering

Tools

ANSYS Fluent

Icepak

Star-CCM+

Job description

Envicool is developing advanced liquid cooling and thermal management solutions for next-generation AI, HPC, and hyperscale data centers. We are seeking a hands-on Thermal Engineer to support testing, validation, failure analysis, and continuous improvement of liquid cooling products and thermal systems.

This role is ideal for candidates with a strong foundation in thermal engineering, hands-on lab experience, and interest in high-power electronics cooling, liquid cooling systems, and data center thermal technologies.

• Support the design, build, and validation of liquid cooling solutions, including cold plates, CDUs, and system-level thermal architectures for high-power electronics and data center applications.
• Set up test instrumentation and execute thermal and fluid performance tests, including temperature, flow rate, pressure, power, and leak-related measurements.
• Conduct failure analysis on components and systems, including leakage, clogging, corrosion, thermal degradation, material compatibility, and reliability-related issues.
• Perform root cause analysis based on experimental data, inspection results, engineering judgment, and cross-functional input.
• Develop and improve test methods, SOPs, validation protocols, data analysis templates, and engineering reports.
• Work closely with engineering, manufacturing, quality, suppliers, and service teams to resolve technical issues and improve product reliability.
• Support customer issue resolution and field failure investigations when needed.
• Master's degree or above in Mechanical Engineering, Thermal Engineering, Materials Science, Energy Engineering, or a related field.
• Strong foundation in heat transfer, fluid mechanics, thermodynamics, and thermal system fundamentals.
• Hands-on laboratory experience in thermal testing, instrumentation, system validation, or experimental diagnostics.
• Experience or strong exposure to failure analysis, root cause analysis, reliability engineering, or quality improvement is preferred.
• Ability to analyze test data and translate findings into practical engineering recommendations.
• Strong problem-solving skills, attention to detail, ownership, and willingness to work in a hands-on lab environment.
• Fluent English communication is required.
• Must be legally authorized to work in the United States.
• Experience with liquid cooling, electronics cooling, server cooling, data center thermal systems, or high-power electronic platforms.
• Familiarity with experimental measurement systems and diagnostics, such as temperature, flow, pressure, power, leak detection, or contamination control.
• Exposure to material or chemical analysis methods, such as SEM-EDS, ICP-OES, DSC, corrosion testing, or coolant/material compatibility evaluation.
• Familiarity with CFD tools such as ANSYS Fluent, Icepak, Star-CCM+, or equivalent is a plus.
• Background in prototype development, lab-scale system integration, troubleshooting, FMEA, or reliability testing is a plus.

4.Location:47730 Westinghouse Dr Fremont, CA 94539