Thermal / Mechanical Engineer – Integrated Rack Power Platform

QuantumScape; San Jose (CA); On-site; USD 180,000 - 230,000; Full time

Job summary

QuantumScape is seeking a Thermal/Mechanical Engineer to own the physical design of a high-density rack power shelf for hyperscale data centers. You will translate battery packs and power electronics into a manufacturable enclosure that fits standard 1U/2U rack spaces and endures demanding thermal environments.

You will run CFD simulations, optimize airflow, and collaborate with Battery Systems Engineering to ensure reliable thermal performance and manufacturability.

Qualifications

• 8+ years designing thermal-mechanical enclosures for rack-mounted power systems and compute platforms.
• Demonstrated expertise with CFD thermal simulation tools including Ansys Icepak, FloTHERM and 6SigmaET.
• Proficiency with SolidWorks or Creo for detailed mechanical design.
• Extensive sheet metal design experience for high-volume manufacturing and tolerance analysis.

Responsibilities

• Design the complete mechanical enclosure (1OU/2OU) using SolidWorks or Creo, including sheet metal chassis, busbar routing, internal supports and external interfaces.
• Solve the core thermal integration for high-power semiconductors and solid-state battery cells with targeted operating temps.
• Perform CFD thermal simulations using Ansys Icepak, FloTHERM and 6SigmaET.
• Optimize airflow under worst-case operating conditions including full electrical load.
• Design to OCP ORv3 mechanical specifications (weight-per-OU, ejector handles, guide rails).
• Develop hot-swap sled mechanisms with proper insertion/extraction force and serviceability.
• Collaborate with Battery Systems Engineering on cell pack mounting and thermal interfaces.
• Lead Design for Manufacturing activities with contract manufacturers (tooling, spot welding, PEM insertion, assembly sequencing).
• Support UL 62368-1 mechanical and flammability requirements for enclosure integrity.

Skills

CFD simulation

SolidWorks/Creo

Sheet metal design

Thermal enclosure design

Data center rack systems

Power electronics cooling

Tools

Ansys Icepak

FloTHERM

6SigmaET

Job description

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 Do

Design the complete mechanical enclosure (1OU or 2OU shelf) using SolidWorks or Creo, including:

• Sheet metal chassis
• Busbar routing
• Internal structural supports
• External connector interfaces

Solve the core thermal challenge of integrating:

• High-power semiconductors and magnetics operating at 100–125°C junction temperatures
• Solid-state battery cells requiring sub-45–60°C operating temperatures
• Directed airflow paths
• Fan selection

Perform CFD thermal simulations using:

• Ansys Icepak
• FloTHERM
• 6SigmaET

Optimize airflow under worst-case operating conditions including:

• Full electrical load

Design to OCP ORv3 mechanical specifications, including:

• Shelf width and depth
• Ejector handle placement
• Guide rail interfaces
• Weight-per-OU limitations

Develop hot-swap sled mechanisms featuring:

• Proper insertion/extraction force curves
• Tool-less serviceability

Collaborate with Battery Systems Engineering on:

• Cell pack mounting
• Compression systems
• Thermal interface materials
• Mechanical isolation within the enclosure

Perform vibration and shock analysis for:

• ISTA 3-Series shipping requirements

Lead Design for Manufacturing (DFM) activities with contract manufacturers, including:

• Tooling
• Spot welding
• PEM fastener insertion
• Assembly sequence optimization

Support UL 62368-1 mechanical and flammability requirements including:

• Enclosure integrity

Interface directly with hyperscaler mechanical integration teams throughout product qualification.

What You Bring

Required Qualifications

8+ years designing thermal-mechanical enclosures for:

• Rack-mounted power systems
• Compute platforms

Demonstrated expertise with CFD thermal simulation tools including:

• Ansys Icepak
• FloTHERM
• 6SigmaET

Proficiency with SolidWorks or Creo for detailed mechanical design.

Extensive sheet metal design experience for high-volume manufacturing, including:

• Punching and stamping
• Spot welding
• Tolerance stack-up analysis

Proven 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 Qualifications

Direct experience with OCP Open Rack / ORv3 mechanical specifications.

Experience with battery pack thermal management in:

• Electric vehicles
• Stationary energy storage
• Telecom backup systems

Exposure to liquid cooling or cold plate design for next-generation rack power shelves.

Experience integrating blind-mate high-power connectors from manufacturers such as:

• TE Connectivity
• Molex

Familiarity with:

• UL 62368-1 mechanical/flammability requirements
• UL 1973 battery enclosure requirements
• Knowledge of IP67 and NEMA ratings for edge or outdoor deployment variants.

Experience with vibration and shock testing to:

• ISTA 3-Series
• GR-63-CORE

Why 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.