Thermal/ Mechanical Engineer, Battery System

QuantumScape Corporation•San Jose, CA

10d•$136,700 - $208,500•Onsite

About The Position

QuantumScape is seeking a Thermal/Mechanical Engineer to own the physical design of their battery system product. This role involves translating circuit boards and battery packs into a manufacturable shelf that fits within a rack, can withstand the data center environment, and is designed for quick servicing. The engineer will be the primary interface with hyperscaler mechanical integration teams during qualification, aiming to compress timelines by understanding and meeting their preferences. This position is crucial for ensuring the physical coexistence of power electronics and battery cells within a compact enclosure.

Requirements

8+ years designing thermal-mechanical enclosures for rack-mount power, compute, or telecom equipment.
Relevant Bachelor’s degree and 9+ years’ experience OR a relevant Master’s degree and 8+ years’ experience OR relevant Ph.D. and 5+ years’ experience.
Demonstrated experience with CFD thermal simulation tools (Ansys Icepak, FloTHERM, or 6SigmaET).
Proficiency in SolidWorks or Creo for detailed mechanical design.
Experience with sheet metal design for volume manufacturing (bend radii, punching/stamping, spot welding, tolerance stackup analysis).
Track record of designs that went through contract manufacturing and passed thermal validation in a production or data center environment.
Understanding of airflow management in forced-convection rack environments.

Nice To Haves

Direct experience with OCP Open Rack/ ORv3 mechanical specifications.
Prior work on battery pack thermal management (EV, stationary storage, or telecom backup).
Exposure to liquid cooling or cold plate design.
Experience with blind-mate connector integration (Amphenol, TE Connectivity, or Molex high-power connectors).
Familiarity with UL 62368-1 mechanical/flammability requirements and UL 1973 battery enclosure requirements.
Knowledge of IP67/NEMA ratings for potential edge or outdoor deployment variants.
Experience with vibration/shock testing per ISTA 3-series or GR-63-CORE.

Responsibilities

Design the complete mechanical enclosure (1OU or 2OU shelf) in SolidWorks or Creo, including sheet metal chassis, busbar routing, internal structural supports, and external connector interfaces.
Solve the core thermal challenge of managing heat from power semiconductors and magnetics (100-125°C junction) while maintaining optimal operating temperatures for solid-state battery cells (sub-45-60°C) through directed airflow, thermal isolation, heat spreaders, and fan selection.
Run CFD simulations using Ansys Icepak, FloTHERM, or 6SigmaET to optimize airflow distribution under worst-case conditions, including full electrical load, high ambient temperatures (35-40°C), and fan degradation scenarios.
Design according to OCP ORv3 mechanical specifications, covering shelf width, depth, connector position, airflow direction, ejector handle placement, guide rail interface, and weight limits per OU.
Develop the hot-swap sled mechanism, ensuring appropriate insertion/extraction forces, blind-mate power connector alignment, and guide rail compliance for tool-less serviceability.
Collaborate with the battery systems engineer on cell pack mounting, compression, thermal interface materials, and mechanical isolation within the enclosure.
Perform vibration and shock analysis for shipping (ISTA 3-series) and seismic requirements (GR-63-CORE or Bellcore Zone 4).
Lead Design for Manufacturing (DFM) engagement with contract manufacturers, focusing on tolerances, tooling, bend radii, spot welding, PEM fastener insertion, and assembly sequence optimization.
Support UL 62368-1 mechanical and flammability requirements, including material selection for 94 V-0, spacing, and enclosure integrity.
Interface directly with hyperscaler mechanical integration teams during qualification reviews.