Principal Mechanical Design Engineer (AI Hardware)

TL;DR

Principal Mechanical Design Engineer (AI Hardware): Develop chassis and line card designs for high-performance networking systems with an accent on tolerance analysis, cooling solutions, and manufacturability. Focus on designing complex electro-mechanical assemblies, ensuring EMI/safety compliance, and supporting connector/cable systems.

Location: San Francisco, CA, United States (onsite; also New York City, NY; North Reading, MA)

Salary: $240,000-$320,000

Company

Well-funded, VC-backed AI/networking hardware startup redefining infrastructure for hyperscalers via Joint Development Model.

What you will do

• Develop chassis and line card designs meeting product, reliability, and scalability requirements.
• Conduct 2D/3D tolerance studies for complex electro-mechanical assemblies.
• Design parts using sheet metal, plastic, die-cast, and extrusion with focus on EMI, safety, and compliance.
• Create CAD models (Creo preferred), PCB outlines, drawings; manage BOMs, ECOs, and part numbers.
• Collaborate with hardware, thermal, CAD, and manufacturing teams to align requirements and mitigate risks.
• Design liquid/forced-air cooling systems and support suppliers for manufacturability.
• Support OSFP/QSFP-DD/OSFP-XD connector and cable harness design for front panels/backplanes.

Requirements

• B.S. or higher in Mechanical Engineering
• 8+ years of mechanical design experience in telecom or data center hardware
• Proficient in Creo (preferred) and SolidWorks
• Strong understanding of EIA, ETSI, and OCP rack standards
• Experience with OSFP/QSFP-DD/OSFP-XD connectors and backplane systems
• Skilled in tolerancing for complex electro-mechanical assemblies

Nice to have

• Familiar with NEBS testing and compliance
• Hands-on with rework tools and mock-up fabrication