About this role
This role is for a highly innovative and hands-on engineer with the ability and drive to design, analyze, and qualify the mechanical and thermal systems that power AWS's next-generation network hardware. You will own the mechanical and thermal design of network devices and racks, from identifying requirements and simulation to building prototypes and driving designs into volume production. This is a hands-on role that requires a self-starter with deep expertise in thermal management and mechanical analysis, and the ability to drive multiple design iterations while diligently converging on the simplest, most reliable, and most cost-effective solution that satisfies the requirements. AWS Infrastructure Services owns the design, planning, delivery, and operation of all AWS global infrastructure. In other words, we're the people who keep the cloud running. We support all AWS data centers and all of the servers, storage, networking, power, and cooling equipment that ensure our customers have continual access to the innovation they rely on. We work on the most challenging problems, with thousands of variables impacting the supply chain — and we're looking for talented people who want to help. You'll join a diverse team of software, hardware, and network engineers, supply chain specialists, security experts, operations managers, and other vital roles. You'll collaborate with people across AWS to help us deliver the highest standards for safety and reliability while providing seemingly infinite capacity at the lowest possible cost for our customers. And you'll experience an inclusive culture that welcomes bold ideas and empowers you to own them to completion. As a Sr. Mechanical/Thermal Engineer within the Network Product Development (NPD) team, you will directly shape how AWS's network infrastructure is built and cooled — at switch, module, and rack level. Key job responsibilities - Identify and analyze thermal and mechanical requirements for network platforms and rack assemblies through collaboration with cross-functional disciplines (electrical, firmware, manufacturing, supply chain). - Conceive and develop trade studies on thermal solutions — including heatsink geometries, fan curves, airflow paths, liquid cooling, and TIM selections — balancing performance, cost, and manufacturability. - Create and iterate detailed 3D CAD models of mechanical and thermal designs — enclosures, sheet metal, heatsinks, fan assemblies, cable management, and rack mounting. - Perform thermal simulations (CFD) and mechanical analyses (classical and FEA — static, dynamic, thermal stress, vibration, shock) for all load conditions and compliance. - Develop test plans throughout development with variable isolation DOEs and statistical analysis for long-term reliability assessments. - Define qualification plans and identify acceptance testing methods appropriate for volume production. - Produce complete design packages — detailed drawings, analysis reports, BOMs, and assembly documentation. - Drive root cause analysis on field failures and work with operations to improve quality processes.