Mechanical Design Engineer

Title: Mechanical Design Engineer Location: San Jose, CA FTE Only15 - 18 years of experience Job Description Thermal Design: Heatsink topology, vapor chambers, heat pipes, fin optimization; fan selection and control; ducting; altitude derating; PoE PSU thermal integration (e.g., 1100W). CFD Expertise: Geometry prep, meshing strategy, solver settings, turbulence models (k-ε/k-ω), boundary condition fidelity; correlation methods and uncertainty analysis. FEA/Structural: Static, modal, buckling, fatigue; fixture/constraint realism; shock/vibe spectra; fastener/joint analysis; compliance with GR-63. Mechanisms & Kinematics: Latches, ejectors, guides, hinges, detents; ergonomics and tactile feedback; wear and tolerance sensitivity. EMC-Aware Mechanics: Shielding architectures, gasket compression, seam leakage control, conductive finishes, grounding paths. GD&T & Tolerance Analysis: Datum strategy, stack-up spreadsheets, worst-case/RSS methods; CMM validation; manufacturable callouts. Materials & Finishes: Thermal and stiffness trade-offs; corrosion and galvanic pairs; finish impacton conductivity/emissions; recyclability. DfM/DfA: Sheet-metal (bends, hems, tabs), die casting (draft/overflow), injection molding (gates,knit lines), secondary ops minimization; Poka-Yoke features. TIMs & Interfaces: Compression targets, surface flatness, roughness; long-term stability; rework/service considerations. Acoustics: Fan tone management, damping/isolators; measurement protocols; psychoacoustic considerations. Reliability & Environment: HALT/HASS, salt-fog, dust/ingress, humidity, temperature cycling; packaging/drop compliance. Documentation Excellence: Clear build guides, service manuals with HMI cues, exploded views, torque specs, and safety notices. Requir ed Skills & Tools: CAD: Creo, SolidWorks, or NX; PDM/PLM (e.g., Agile/Windchill) Analysis: CFD (6Sigma/Flotherm/Icepak), FEA (Ansys/Nastran) Standards: NEBS, IEC/UL, RoHS/REACH, IP/ingress Methods: DfM/DfA, GD&T, Tolerance Analysis, RCCA/8D Expertise in Sheet-metal, die casting, injection molding, thermal interface materials (TIMs), heatsinks/vapor chambers Qualifications: Bachelor's/master's in mechanical engineering 15+ years in mechanical design for networking or server-class hardware Experience with high-power thermal solutions and acoustic optimization

Created: 2026-04-02