Thermal-Mechanical Manufacturing Engineer

About the TeamOpenAI’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.About the RoleWe’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.In this role, you will:Lead thermal-mechanical manufacturing and quality initiatives to ensure product success from concept through launch and high-volume productionOwn manufacturing process design for next-generation AI hardware systems, partnering with engineering, operations, TPMs, suppliers, and external vendorsCollaborate cross-functionally to design and optimize mechanical and thermal solutions for large-scale data center deploymentDesign and validate manufacturing processes for chassis, enclosures, cooling systems, and high-power connections, ensuring alignment with performance and reliability standardsProvide hands-on DFM/DFx analysis across design, development, prototyping, testing, and production phasesResearch and implement automation techniques to improve manufacturing efficiency and scalabilityDefine and manage manufacturing requirements, scope, schedules, and deliverables in coordination with internal and external stakeholdersPartner with suppliers to develop validation plans that ensure reliability and quality goals are metDrive problem-solving efforts, including risk assessment, mitigation planning, and change managementLead new product introduction (NPI) efforts and production ramp, ensuring compliance with relevant quality standards and regulationsDevelop specifications and test procedures to validate reliability and performance of electronic systemsMentor engineers and collaborate with suppliers to design and deliver high-quality mechanical and thermal systemsManage multiple programs simultaneously and ensure execution against timelines and standardsYou might thrive in this role if you have: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 hardwareStrong proficiency in CAD tools and FEADeep understanding of mechanical design, materials, manufacturing methods, and validation test proceduresExperience analyzing experimental data, identifying root causes, and implementing corrective actionsStrong first-principles problem-solving skills to support design and manufacturing decisionsAbility to operate independently while collaborating effectively in cross-functional environmentsPreferred Qualifications10+ years of experience in manufacturing engineering for IT hardware or high-performance computing systemsExperience with data center hardware deployed at scalePractical experience co-developing advanced cooling technologiesDeep expertise in reliability testing, failure analysis, and thermal stress modeling for electronic compo ... (truncated, view full listing at source)