Systems Senior Staff Engineer

Flex•Littleton, MA

12h

About The Position

At JetCool, a Flex company, we’re at the forefront of liquid cooling innovation, delivering advanced solutions that empower our partners in AI and high-performance computing. United by a shared purpose, our teams are pushing the limits of what’s possible and tackling complex challenges. A career at JetCool offers the opportunity to make a real impact by helping build smarter, more sustainable data centers. Together, we’re not just advancing technology — we’re redefining cooling standards to create a more sustainable tomorrow. Job Summary To support our extraordinary teams who build great products and contribute to our growth, we’re looking to add a Senior Thermal Systems Engineer located in Littleton, MA. Reporting to the Product Manager the Senior Thermal Systems Engineer will own the end-to-end architecture, analysis, validation, and deployment of direct-to-chip (D2C) cooling systems used to cool high-TDP CPUs/GPUs/accelerators. They will be the technical leader partnering with Product Management, Mechanical/Electrical Engineering, Manufacturing, Quality, Reliability, and key customers to deliver robust, scalable products that meet performance, reliability, and cost targets. What a typical day looks like: Own thermal architecture & modeling Define system-level thermal requirements (TDP range, ΔT, coolant temperature, flow rate, pressure drop, acoustic & power budgets). Apply first principles in fluid dynamics and heat transfer to analyze design concept thermal performance Build and validate 1D/3D models (e.g., FloEFD, Icepak, MacroFlow, ANSYS Fluent, COMSOL) for cold plates, manifolds, quick-disconnects (QDs), pumps, and CDUs. Perform sensitivity trade-offs (flow distribution, fin geometry, microchannel optimization, TIM selection, manifold topology). Design liquid cooling subsystems Specify and refine cold plates, CDUs, manifolds, hoses/QDs, reservoirs, filters, sensors, and controls. Collaborate with ME/EE on mechanical stack-up, materials, corrosion mitigation (galvanic compatibility), and leak risk reduction. Define DFX (DFM/DFA/DFT) and lead EVT/DVT/PVT from prototypes to mass production. Validate and qualify Develop test plans for thermal performance, pressure integrity, leak detection, long-term reliability (HALT/HASS), and contamination control (particulates, biogrowth). Execute lab and rack-scale testing (pump curves, flow balance, ΔP mapping, heat load emulation, transient behavior). Drive failure analysis and corrective actions (FMEAs, 8D/PPS). Partner across the business Work with Product Management on PRDs, roadmaps, and business cases. Support manufacturing process development (leak/pressure test stations, purge and fill, cleanliness criteria) and supplier selection/qualification. Engage with customers: define requirements, run pilots, analyze fleet telemetry, and support deployment at scale.

Requirements

BS/MS in Mechanical Engineering or Aerospace Engineering or related field (PhD a plus)
5+ years experience in thermal design/validation for high-power electronics (preferably data center/server/HPC)
Excellent first principles knowledge in fluid dynamics, thermodynamics, and heat transfer
Proven expertise in liquid cooling, including CFD, pressure drop/flow modeling, and thermal metrology
Hands-on with lab instrumentation (flow meters, pressure transducers, thermocouples/RTDs, DAQ, leak detectors) and test automation (Python, LabVIEW, or similar)
Experience bringing products from EVT → DVT → PVT → ramp, including DFX and supplier engagement
Excellent technical communication and documentation skills

Responsibilities

Own thermal architecture & modeling
Define system-level thermal requirements (TDP range, ΔT, coolant temperature, flow rate, pressure drop, acoustic & power budgets)
Apply first principles in fluid dynamics and heat transfer to analyze design concept thermal performance
Build and validate 1D/3D models (e.g., FloEFD, Icepak, MacroFlow, ANSYS Fluent, COMSOL) for cold plates, manifolds, quick-disconnects (QDs), pumps, and CDUs
Perform sensitivity trade-offs (flow distribution, fin geometry, microchannel optimization, TIM selection, manifold topology)
Design liquid cooling subsystems
Specify and refine cold plates, CDUs, manifolds, hoses/QDs, reservoirs, filters, sensors, and controls
Collaborate with ME/EE on mechanical stack-up, materials, corrosion mitigation (galvanic compatibility), and leak risk reduction
Define DFX (DFM/DFA/DFT) and lead EVT/DVT/PVT from prototypes to mass production
Validate and qualify
Develop test plans for thermal performance, pressure integrity, leak detection, long-term reliability (HALT/HASS), and contamination control (particulates, biogrowth)
Execute lab and rack-scale testing (pump curves, flow balance, ΔP mapping, heat load emulation, transient behavior)
Drive failure analysis and corrective actions (FMEAs, 8D/PPS)
Partner across the business
Work with Product Management on PRDs, roadmaps, and business cases
Support manufacturing process development (leak/pressure test stations, purge and fill, cleanliness criteria) and supplier selection/qualification
Engage with customers: define requirements, run pilots, analyze fleet telemetry, and support deployment at scale