Senior Staff Mechanical Systems Engineer (Spark)

• Crusoe is a vertically integrated AI Factory company with a mission to accelerate the abundance of energy and intelligence
• Our competitive advantage—“Speed is the only moat”—is directly tied to our ability to rapidly design, build, and deploy high-density modular power and compute infrastructure
• Embedded directly within the Spark Modular Data Center (MDC) Business Unit, the Senior Staff Mechanical Systems Engineer - Spark is a key technical engine supporting the mechanical, thermal, and fluid architecture of our MDC platform
• You will sit at the crossroads of hardware, software, and physical infrastructure translating next-generation GPU compute workloads, cluster topologies, power envelopes, and cooling requirements into robust, high-performance liquid-cooled MDC system designs
• In this role, you will support the technical execution of current and future MDC architectures, collaborating closely with external design & engineering partners and internal R&D, Crusoe Industries (CI), Cloud Product, and Cloud Engineering teams to turn first-principles mechanical design into scalable product reality
• Liquid Cooling System Design: Own system-level design for direct-to-chip (DLC) and hydronic infrastructure, including Coolant Distribution Units (CDUs), primary/secondary loops, flow rate balancing, pressure drop calculations, manifolds, and leak-detection mechanisms. Perform the thermal and fluid calculations — heat load modeling, flow network analysis, pump/heat-exchanger sizing — that turn GPU rack power and cooling requirements into concrete mechanical specifications
• First-Principles Mechanical Integration: Apply core mechanical engineering principles — fluid dynamics, thermodynamics, structural mechanics, vibration/transportation dynamics — to optimize containerized envelope design, structural integrity, and environmental resiliency
• Engineering Partner Engagement: Work with external design & engineering partners and internal teams to review, iterate, and refine CAD models, BIM files, 30/60/90/100% drawing packages, and manufacturing-ready documentation
• Design for Manufacturability (DFM): Partner with Crusoe Industries (CI) and Contract Manufacturers (CMs) to optimize pipe racks, modular connections, skid assemblies, and structural mating for rapid factory assembly and field commissioning
• Spark Platform Evolution: Drive the mechanical and thermal roadmap for future Spark generations, moving from current air-cooled baselines to next-gen high-density liquid-cooled architectures
• Mechanical–Thermal Interface Ownership: Own the mechanical design as it interfaces with compute, power, and networking constraints — working closely with thermal and electrical specialists to ensure rack layout, cabling, and enclosure design are mechanically sound and thermally validated. Serve as the mechanical design authority translating early-stage liquid-cooling concepts into manufacturable production units
• Sustaining Engineering & Continuous Improvement: Provide sustaining mechanical engineering support for deployed and in-production Spark assets — investigating field issues, resolving design or component issues, implementing engineering change orders (ECOs), and feeding field learnings back into future design iterations

Benefits

• Health & wellbeing: Comprehensive health benefits designed to support your overall wellness
• Time away: Paid time off for vacations, family bonding, and unexpected needs
• 401(k) match: Build your financial future with our 401(k) matching program
• Mental wellness: Resources and support for your emotional wellbeing and navigating life’s challenges- Direct experience designing, validating, or integrating complex liquid-cooling loops (DLC, CDUs, pumping skids, heat exchangers, or hydronic systems)
• Working knowledge of relevant mechanical codes and standards (e.g., ASME B31.x piping codes, ASHRAE thermal guidelines, NFPA data center cooling requirements)
• Bachelor’s degree in Mechanical Engineering or a related field; Master’s degree a plus
• Proficiency with mechanical CAD tools (e.g., SolidWorks, Creo, or Inventor) and familiarity with thermal-fluid simulation tools (e.g., ANSYS Fluent/CFX, 6SigmaET, or equivalent)
• 8-12 years of mechanical engineering experience, with deep, hands-on expertise in fluid mechanics, heat transfer, structural integrity, and mechanical system dynamics
• Demonstrated experience collaborating with external design & engineering partners while contributing to internal design iterations and CAD review workflows
• Comfort navigating fast-moving environments where physical hardware and compute infrastructure are co-developed concurrently
• Strong working understanding of thermal engineering fundamentals (heat transfer, CFD/thermal modeling concepts) sufficient to collaborate closely and speak the same technical language as dedicated thermal engineers — you don’t need to be the thermal expert, but you need to design mechanical systems that hold up under their analysis
• Direct experience in modular data center design
• Background in complex adjacent industries such as aerospace, automotive, energy, or industrial process hardware
• Familiarity with BIM workflows and full-lifecycle drawing packages (30/60/90/100%)
• Experience leading design-for-manufacturability efforts with contract manufacturers
• Professional Engineer (PE) license