Senior Staff Thermal Design Engineer

d-Matrix

. Lead end-to-end thermal design, architecture, and validation for next-generation AI XPU computing platforms .

Posted 10/22/2026full-timeSanta Clara • California • United StatesSenior💰 $175,000 - $265,000 per yearWebsite

Core Competencies

Role fit

Core Competencies

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Demonstrates expertise in thermal design and validation for AI XPU computing platforms, with a strong focus on liquid cooling hardware and fluid dynamics analysis. Proficient in CFD modeling and performance testing of thermal solutions, ensuring integration with mechanical and electrical systems.

Highest-signal resume keywords

Thermal DesignCFD ModelingLiquid Cooling HardwareFluid Dynamics AnalysisPerformance Testing

ATS Keywords

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Applicant Tracking System Keywords

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Hard Skills

Thermal DesignCFD ModelingFluid Dynamics AnalysisPressure Drop CalculationsAir-Cooled Thermal ManagementPerformance CharacterizationStress TestingCold Plate DesignHeat Sink DesignFlow Network Analysis

Tools & Technologies

Simcenter FlothermFlotherm XTAnsys IcepakAnsys FluentPTC CreoSolidWorksSiemens NXFlownexFlowmasterMulti-Channel DAQs

Industry Keywords

AI XPU Computing PlatformsLiquid Cooling StandardsThermal ManagementClosed-Loop Cooling CircuitsOpen Compute ProjectReliability MetricsThermal Test VehiclesFlow BenchesPressure CalibrationTIM1

Tech Stack

Tools & technologies

Airflow

About the role

Key responsibilities & impact

Lead end-to-end thermal design, architecture, and validation for next-generation AI XPU computing platforms
Lead thermal-fluid design and development of liquid cooling hardware, including XPU cold plates, rack manifolds, quick disconnects, and tubing networks
Define and select internal and external Coolant Distribution Units
Perform fluid dynamics and flow network analysis to balance flow, minimize pressure drop, and prevent flow starvation across multi-chassis racks
Evaluate fluid compatibility, materials, corrosion inhibitors, and long-term reliability of closed-loop cooling circuits
Design and optimize air-cooled thermal solutions, including heat sinks, fans, ducting, chassis airflow, and VRM/memory cooling
Build 3D CFD models and 1D hydraulic network simulations to predict temperatures, thermal resistance, and rack-level pressure drop
Architect thermal/fluid lab setups and instrument test vehicles and chassis
Execute performance testing of cold plates, manifolds, CDUs, and server/rack systems under varied workloads and ambient conditions
Partner with Mechanical, Electrical, Packaging, and Reliability teams to integrate thermal components into production-ready AI servers and racks

Requirements

What you’ll need

Bachelor’s, Master’s, or Ph.D. in Mechanical Engineering, Thermal Engineering, Aerospace Engineering, or a related discipline
7+ years of hands-on experience in thermal design, CFD modeling, and physical testing of air-cooled and liquid-cooled electronic systems
Expertise designing, selecting, and qualifying cold plates, rack manifolds, fluid tubing, UQDs, and CDUs
Understanding of flow networks, pressure drop calculations, hydraulic balancing, and fluid distribution across multi-socket, multi-tray server racks
Knowledge of air-cooled thermal management, including fan selection, heat sink design, and system impedance testing
Experience with Simcenter Flotherm, Flotherm XT, Ansys Icepak, or Ansys Fluent
Knowledge of multi-channel DAQs, thermal test vehicles, flow benches, pressure calibration, and helium/pressure leak testing
Experience performing hands-on performance characterization and stress testing of liquid-cooled hardware
Experience with Flownex or Flowmaster is preferred
Proficiency with PTC Creo, SolidWorks, or Siemens NX is preferred
Familiarity with Open Compute Project liquid cooling standards and industry reliability metrics is preferred
Knowledge of TIM1, TIM1.5, phase-change materials, HBM, interposers, and multi-die modules is preferred
Must be legally authorized to work in the United States
Must address whether immigration-related employment sponsorship is required

Benefits

Comp & perks

Equity
Bonus/incentive opportunities based on individual and company performance
Medical insurance
Dental insurance
Vision insurance
401(k)
Inclusive rewards plan supporting employee wellbeing and their loved ones