Thermal/ Mechanical Engineer

QuantumScape Corporation•San Jose, CA

12h•Onsite

About The Position

QuantumScape is 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. As Thermal/ Mechanical Engineer, you will own the physical design of the product, translating circuit boards and battery packs into a manufacturable shelf that fits the rack, survives the data center environment, and can be serviced by a technician in seconds. This role is critical because hyperscalers have strict requirements for rack geometry, cooling, and serviceability. Your design fluency with their unwritten preferences can significantly compress the qualification timeline. You will be the person who makes coexistence physically possible for power electronics and battery cells sharing a tight enclosure.

Requirements

8+ years designing thermal-mechanical enclosures for rack-mount power, compute, or telecom equipment
Demonstrated experience with CFD thermal simulation tools (Ansys Icepak, FloTHERM, or 6SigmaET)
Proficiency in SolidWorks or Creo for detailed mechanical design
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 (emerging trend for rack power shelves)
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: sheet metal chassis, busbar routing, internal structural supports, and external connector interfaces
Solve the core thermal challenge: power semiconductors and magnetics (tolerant to 100-125°C junction) sharing an enclosure with solid-state battery cells (requiring sub-45-60°C operation) - via directed airflow paths, thermal isolation zones, heat spreaders, and fan selection
Run CFD simulations (Ansys Icepak, FloTHERM, or 6SigmaET) to optimize airflow distribution under worst-case conditions: full electrical load, 35-40°C inlet air (ASHRAE A1/A2), fan degradation scenarios
Design to OCP ORv3 mechanical specifications: shelf width, depth, connector position, airflow direction (front-to-back), ejector handle placement, guide rail interface, and weight-per-OU limits
Develop the hot-swap sled mechanism with proper insertion/extraction force curves, 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 DFM engagement with contract manufacturers: tolerances, tooling, bend radii, spot welding, PEM fastener insertion, and assembly sequence optimization
Support UL 62368-1 mechanical and flammability requirements (material selection for 94 V-0, spacing, enclosure integrity)
Interface directly with hyperscaler mechanical integration teams during qualification reviews