Thermal Design Engineer, AI Hardware

Tesla is seeking a Thermal Design Engineer to support its AI Hardware team and next-generation Dojo AI data centers. The role focuses on designing and validating air and liquid cooling solutions for high-density AI hardware, optimizing thermal systems, developing hydraulic and thermal models, and collaborating across chip, tray, rack, and infrastructure design.

What you'll do:

• Design passive and active cooling solutions for high power AI electronics in compute tray
• Provide thermal inputs to the layout and design of the compute tray electronics and air/coolant delivery
• Drive component selection of thermal system from chip level (TIM, Heat Spreader, heatsink/coldplate) to tray level (fans, hoses, manifolds, QDs) to system level (CDU, Pump, Filter, Sensors)
• Design and optimize cooling solutions for performance, cost, reliability and risk
• Balance flow in complex flow networks at rack and compute tray levels by developing analytical and computational models of hydraulic and thermal systems
• Define thermal policy/ control algorithms and characterize system response at different scales
• Contribute to module- and system-level validation and reliability testing and data analysis including test plan , setup and debug

What they're looking for:

• - Degree in Thermal or Mechanical Engineering, or equivalent experience demonstrating exceptional ability in thermal management
• - Minimum 2 years of industrial experience with evidence of exceptional performance
• - Strong understanding of fundamentals of fluid mechanics, heat transfer, and thermodynamics
• - Proficiency in numerical simulation of heat transfer and fluid flow
• - Define thermal policy and control algorithms and characterize system response at different scales
• - Experience in data centers liquid and air cooling of high-power GPU/ASICs, system flow balance and thermal control
• - Knowledge of semiconductor packaging and package-level thermal/mechanical interactions

Benefits:

• Medical plans with plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental, including orthodontic coverage, and vision plans, both with options with a $0 paycheck contribution
• Company-paid Health Savings Account (HSA) contribution when enrolled in the High-Deductible medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match
• Employee Stock Purchase Plans and other financial benefits
• Company-paid Basic Life and AD&D insurance
• Short-term and long-term disability insurance with a 90-day waiting period
• Employee Assistance Program