Thermal-Mechanical Manufacturing Engineer

OpenAI•San Francisco, CA

2d•Hybrid

About The Position

OpenAI’s Hardware organization develops system-level and silicon solutions designed for the unique demands of advanced AI workloads. We work at the intersection of mechanical, thermal, electrical, and systems engineering to bring high-performance, mission-critical hardware from concept through mass production. Our team partners closely with design engineering, operations, TPM, and external manufacturing partners to ensure our AI infrastructure is reliable, efficient, and built to scale. We’re looking for an experienced Manufacturing Engineer to lead thermal-mechanical manufacturing initiatives across the lifecycle of next-generation AI hardware systems. In this role, you will drive manufacturing process design, validation, and quality strategy from early concept through launch and mass production. You will work cross-functionally with mechanical, thermal, electrical, and systems engineers to ensure our data center hardware platforms meet performance, reliability, and scalability requirements at both component and rack levels. This role requires strong analytical rigor, hands-on manufacturing experience, and the ability to execute in a fast-paced, cross-disciplinary environment. This role is based in San Francisco, CA. We use a hybrid work model of 3 days in the office per week and offer relocation assistance to new employees.

Requirements

Bachelor’s degree in Mechanical Engineering or a related field (Master’s preferred)
7+ years of industry experience in manufacturing engineering, mechanical design, simulation, and validation for IT hardware
Strong proficiency in CAD tools and FEA
Deep understanding of mechanical design, materials, manufacturing methods, and validation test procedures
Experience analyzing experimental data, identifying root causes, and implementing corrective actions
Strong first-principles problem-solving skills to support design and manufacturing decisions
Ability to operate independently while collaborating effectively in cross-functional environments

Nice To Haves

10+ years of experience in manufacturing engineering for IT hardware or high-performance computing systems
Experience with data center hardware deployed at scale
Practical experience co-developing advanced cooling technologies
Deep expertise in reliability testing, failure analysis, and thermal stress modeling for electronic components
Experience working closely with suppliers and manufacturing partners to support new technology development and production ramp

Responsibilities

Lead thermal-mechanical manufacturing and quality initiatives to ensure product success from concept through launch and high-volume production
Own manufacturing process design for next-generation AI hardware systems, partnering with engineering, operations, TPMs, suppliers, and external vendors
Collaborate cross-functionally to design and optimize mechanical and thermal solutions for large-scale data center deployment
Design and validate manufacturing processes for chassis, enclosures, cooling systems, and high-power connections, ensuring alignment with performance and reliability standards
Provide hands-on DFM/DFx analysis across design, development, prototyping, testing, and production phases
Research and implement automation techniques to improve manufacturing efficiency and scalability
Define and manage manufacturing requirements, scope, schedules, and deliverables in coordination with internal and external stakeholders
Partner with suppliers to develop validation plans that ensure reliability and quality goals are met
Drive problem-solving efforts, including risk assessment, mitigation planning, and change management
Lead new product introduction (NPI) efforts and production ramp, ensuring compliance with relevant quality standards and regulations
Develop specifications and test procedures to validate reliability and performance of electronic systems
Mentor engineers and collaborate with suppliers to design and deliver high-quality mechanical and thermal systems
Manage multiple programs simultaneously and ensure execution against timelines and standards