Sr. Mechanical Engineer - Thermal - United States

Location(s): Lisle, IllinoisCompany: MolexCareer Field: EngineeringJob Number: 192916Apply: JobAs part of Molex's strategic investment in CAEPlus and the ongoing development of next-generation AI data center thermal management solutions, this position will operate in a unique collaboration model between the two organizations. While employed by Molex and receiving all Molex employment benefits, the successful candidate will work closely with the CAEPlus team and focus primarily on advancing CAEPlus technologies, products, and innovation initiatives. This role offers the entrepreneurial environment of a growing technology venture combined with the resources, stability, and engineering expertise of a global industry leader.This role leads the mechanical design, product validation, and manufacturing development of BoundaryCool thermal management solutions for the CAEPlus Phase I program. The engineer will own the detailed design of cold plates, active module integration geometry, and manufacturing drawings — driving the full product development lifecycle from concept through prototype validation. Working directly with the CAEPlus founder and cross-functional program team, this individual will apply expertise across precision machining, materials, and thermal hardware design to bring a breakthrough active cooling platform to market.What You Will DoDesign and apply advanced fluid dynamic concepts into the active thermal management system to enhance convective heat transfer performance of cold plates and related thermal solutionsDevelop and validate CFD simulations of the active thermal management system, including turbulence modeling, Conjugate Heat Transfer (CHT) analysis, heat transfer coefficient improvement, and flow distribution characterizationDesign and execute single and multi-cold plate flow loop test protocols — measuring thermal resistance (Rth K/W), flow impedance, and pressure drop (ΔP) across target flow rate range, consistent with Open Compute Project (OCP) standardsDesign server chassis-level and rack-level test rig configurations for NVIDIA NVL-class GPU load simulationSet up and operate flow loop test rig (coolant loop assembly, instrumentation, leakage detection, and data acquisition system)Install and calibrate thermal instrumentation including thermocouples, pressure transducers, flow meters, and power measurement equipmentCorrelate CFD simulation results with experimental thermal test data and iterate on the active cooling system to improve performanceCollaborate with Mechanical Engineers and CAD Designers on cold plate channel geometry and active cooling system designDevelop thermal test protocols, acceptance criteria, data acquisition procedures, and documentation of best practices for simulation and testingGenerate performance data package documenting Rth, ΔT, ΔP, and flow uniformity for customer qualificationSpecify fluid fitting requirements and standards, including Universal Quick Disconnects (UQD), G1/4" BSPP, NPT and equivalent connector specifications for inlet and outlet interfacesDiscover and invent new techniques and methods in thermal simulation, design, and testingSupport technical paper authorship and patent filing in thermal management and active coolingWho You Are (Basic Qualifications)BS in Mechanical Engineering, Thermal Sciences, or Aerospace Engineering3+ years of thermal engineering and CFD simulation experienceProficiency in ANSYS Fluent, ANSYS Icepak, Simcenter FloTherm, COMSOL, or equivalent thermal simulation toolsExperience with liquid cooling system design and analysis — single-phase and two-phaseExperience setting up and operating thermal test rigs, instrumentation, and data acquisition systemsStrong foundation in heat transfer (conduction, forced convection, radiation, and two-phase heat transfer)Experience with 3D CAD tools for simulation geometry preparation and model validationWhat Will Put You AheadMS or PhD in Mechanical Engineering, Thermal Sciences, or Aerospace EngineeringExperience with direct liquid cooling (DLC) or direct-to-chip (D2C) cold plate systemsExperience with ANSYS Fluent UDFs or Python scripting for simulation automationFamiliarity with Coolant Distribution Unit (CDU) systems and chiller systems used in hyperscale data center environmentsFamiliarity with Open Compute Project (OCP) liquid cooling standard protocolsFamiliarity with NVL-class or HGX-class GPU thermal specifications and test methodologiesFamiliarity with two-phase cooling systems and simulation methodologiesPrior experience publishing technical papers or filing patents in thermal management or active coolingFor this role, we anticipate paying $100,000 - $130,000 per year. This role is eligible for variable pay, issued as a monetary bonus or in another form.At Koch companies, we are entrepreneurs. This means we openly challenge the status quo, find new ways to create value and get rewarded for our individual contributions. Any compensation range provided for a role is an estimate determined by available market data. The actual amount may be higher or lower than the range provided considering each candidate's knowledge, skills, abilities, and geographic location. If you have questions, please speak to your recruiter about the flexibility and detail of our compensation philosophy.Hiring PhilosophyAll Koch companies value diversity of thought, perspectives, aptitudes, experiences, and backgrounds. We are Military Ready and Second Chance employers. Learn more about our hiring philosophy here.Who We AreAt Koch, employees are empowered to do what they do best to make life better. Learn how our business philosophy helps employees unleash their potential while creating value for themselves and the company.Our BenefitsOur goal is for each employee, and their families, to live fulfilling and healthy lives. We provide essential resources and support to build and maintain physical, financial, and emotional strength - focusing on overall wellbeing so you can focus on what matters most. Our benefits plan includes - medical, dental, vision, flexible spending and health savings accounts, life insurance, ADD, disability, retirement, paid vacation/time off, educational assistance, and may also include infertility assistance, paid parental leave and adoption assistance. Specific eligibility criteria is set by the applicable Summary Plan Description, policy or guideline and benefits may vary by geographic region. If you have questions on what benefits apply to you, please speak to your recruiter.Additionally, everyone has individual work and personal needs. We seek to enable the best work environment that helps you and the business work together to produce superior results.Equal OpportunitiesEqual Opportunity Employer, including disability and protected veteran status. Except where prohibited by state law, some offers of employment are conditioned upon successfully passing a drug test. This employer uses E-Verify. Please click here for additional information. (For Illinois E-Verify information click here, aquí, or tu).#LI-RL1