Thermal/Mechanical Engineer

Heatscape Inc.; Morgan Hill (CA); Hybrid; USD 110,000 - 150,000; Full time

Job summary

Heatscape, LLC, based in Morgan Hill, designs and manufactures custom heat sinks and thermal solutions for AI, data center, and high-performance electronics. This mid-level engineer role blends hands-on CFD, CAD, lab testing, and manufacturing coordination with customers, suppliers, and engineering teams.

You will turn incomplete inputs into scalable, manufacturable heatsink solutions, define requirements, and drive prototypes through to production, with hybrid work and domestic/international

Qualifications

• Bachelor's degree in Mechanical, Thermal, Aerospace Engineering, or a closely related discipline.
• 3+ years of relevant experience in electronics cooling, thermal management, mechanical product development, CFD, or test/validation.
• Hands-on experience setting up, meshing, running, troubleshooting, and explaining models in a commercial CFD or thermal-analysis tools.
• Working proficiency in 3D CAD and the ability to create or review mechanical drawings, assemblies, tolerances, and basic GD&T.
• Strong understanding of heat transfer and fluid mechanics, including conduction, convection, thermal interfaces, airflow, and pressure drop.
• Clear written and verbal communication; sound judgment, highly inquisitive and resourceful, comfort with changing priorities, regular Morgan Hill presence, and a team-first, multi-contributor mindset.

Responsibilities

• Own programs from technical intake through heatsink prototype validation and production handoff; define requirements, assumptions, risks, actions, and revisions.
• Translate PCB layouts, mechanical envelopes, keep-outs, heat source maps, airflow conditions, mounting requirements, and TIM interfaces into clear thermal/mechanical design requirements.
• Build and run hands-on CFD models: simplify geometry; define materials and boundary conditions; mesh, solve, debug, post-process, run sensitivity studies, and correlate to test data.
• Plan and run lab tests using controlled heat sources/TTVs, test instrumentation, DAQs, wind-tunnel/fan equipment and liquid loops; bridge the gap between models and real test results.
• Create and modify 3D CAD models of heat sinks and related assemblies; prepare or review 2D drawings, dimensions, tolerances, basic GD&T, BOMs, mounting stack-ups, and critical interfaces.
• Develop and compare extruded, skived, zipper fin, machined, bonded fin, and actively cooled heat sink concepts utilizing heat pipes, vapor chambers, and cold plates.
• Use CFD, calculations, and test data to optimize fin geometry, base thickness, materials, TIM selection, mounting load, airflow, and fan selection.
• Coordinate DFM reviews with international design team, suppliers, and manufacturing partners; support prototype builds, design revisions, and production handoff.
• Document assumptions, risks, results, and recommendations clearly; support customer technical reviews and hands-on thermal testing as needed.

Skills

Thermal management

CFD

3D CAD

Heat transfer

Problem solving

Team collaboration

Education

Bachelor's degree in Mechanical Engineering, Thermal/ Aerospace

Tools

FloTHERM

FLOEFD

ANSYS Icepak/Fluent

LabVIEW

Python automation

Job description

Heatscape, LLC designs and manufactures custom chip and board level thermal solutions for high performance electronics. We serve AI/data center, semiconductor, networking, telecom, storage, industrial, and power-electronics markets. Heatscape is private-equity owned and growing, with engineering in Morgan Hill, a global design and manufacturing team.

THE ROLE

Model it. Build it. Test it. Carry it into production.

This mid-level "Swiss-army-knife" engineer performs hands-on CFD, CAD, lab testing, customer support, and manufacturing coordination. You will turn incomplete customer inputs into scalable and manufacturable heatsink solutions while working directly with engineers, customers, executives, suppliers, and factories in a team-first environment.

Key Responsibilities

• Own programs from technical intake through heatsink prototype validation and production handoff; define requirements, assumptions, risks, actions, and revisions.
• Translate PCB layouts, mechanical envelopes, keep-outs, heat source maps, airflow conditions, mounting requirements, and TIM interfaces into clear thermal/mechanical design requirements.
• Build and run hands-on CFD models: simplify geometry; define materials and boundary conditions; mesh, solve, debug, post-process, run sensitivity studies, and correlate to test data.
• Plan and run lab tests using controlled heat sources/TTVs, test instrumentation, DAQs, wind-tunnel/fan equipment and liquid loops; bridge the gap between models and real test results.
• Create and modify 3D CAD models of heat sinks and related assemblies; prepare or review 2D drawings, dimensions, tolerances, basic GD&T, BOMs, mounting stack-ups, and critical interfaces.
• Develop and compare extruded, skived, zipper fin, machined, bonded fin, and actively cooled heat sink concepts utilizing heat pipes, vapor chambers, and cold plates.
• Use CFD, calculations, and test data to optimize fin geometry, base thickness, materials, TIM selection, mounting load, airflow, and fan selection.
• Coordinate DFM reviews with international design team, suppliers, and manufacturing partners; support prototype builds, design revisions, and production handoff.
• Document assumptions, risks, results, and recommendations clearly; support customer technical reviews and hands-on thermal testing as needed.

What Success Looks Like

• Turns incomplete inputs into a clear technical plan, credible CFD model, and manufacturable CAD design.
• Connects simulation, calculations, CAD, prototype hardware, measured data, and manufacturing constraints.
• Delivers accurate design records and concise recommendations that keep programs moving.

Minimum Qualifications

• Bachelor's degree in Mechanical, Thermal, Aerospace Engineering, or a closely related discipline.
• 3+ years of relevant experience in electronics cooling, thermal management, mechanical product development, CFD, or test/validation.
• Hands-on experience setting up, meshing, running, troubleshooting, and explaining models in a commercial CFD or thermal-analysis tools.
• Working proficiency in 3D CAD and the ability to create or review mechanical drawings, assemblies, tolerances, and basic GD&T.
• Strong understanding of heat transfer and fluid mechanics, including conduction, convection, thermal interfaces, airflow, and pressure drop.
• Clear written and verbal communication; sound judgment, highly inquisitive and resourceful, comfort with changing priorities, regular Morgan Hill presence, and a team-first, multi-contributor mindset.

Preferred Experience

• Direct design experience with heat sinks, fansinks, heat pipes, vapor chambers, cold plates, or high heat flux semiconductor applications.
• FloTHERM, FLOEFD, ANSYS Icepak/Fluent, LabVIEW/Python automation, including correlation to laboratory data.
• Heat sink manufacturing processes such as extrusion, skiving, zipper fin construction, machining, soldering, brazing, plating, and anodizing.
• Thermal lab testing, customer facing engineering, and coordination with overseas engineering and manufacturing teams.

Work Model & Travel: Full-time hybrid role with Morgan Hill as the engineering home base. Regular onsite work is required for lab testing and hardware reviews. Domestic and international travel may include customer project reviews, supplier engagement, factory visits, and production launches.

Total Compensation Range: Base: $110,000-$150,000 | Annual incentive: target 10% | Benefits include medical, dental, vision, retirement/401k match, PTO, and paid holidays. Actual compensation depends on experience, skills, and eligibility.