Sr Mechanical Finite Element Analysis; FEA Engineer

Position: Sr Mechanical Finite Element Analysis (FEA) Engineer
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Senior Mechanical Finite Element Analysis (FEA) Engineer At SA Technologies Inc., we believe in turning career aspirations into reality. As a CMMI Level 5 and Great Place to Work Certified global IT consulting and services company-and recognized as one of the Best Places for Women-we are committed to building an inclusive, supportive, and high-performance workplace

Job Description Role

Summary:

We are looking for a Senior Mechanical Finite Element Analysis (FEA) Engineer with a deep understanding of structural and material modeling to lead the development of next-generation cooling solutions in Liquid Jet Datacenter Solutions. You will drive mechanical architecture and compliance of Frore Systems' cutting-edge cooling solutions across servers and racks, ensuring scalable, energy-efficient, and reliable cooling for high-density workloads, specifically xPUs for AI/ML and HPC.

This position is onsite at the Frore Systems HQ in San Jose, CA.

Key Responsibilities:

Lead the development of advanced FEA methodologies to assess structural integrity, performance, and durability of liquid cooling systems. Collaborate with multi-disciplinary engineering teams to define analysis requirements and ensure alignment with product specifications and performance goals. Conduct complex simulations using industry-standard FEA software (ANSYS) to evaluate mechanical performance under various loading conditions. Model Creep, large deformation and other non-linear material behavior in metals.

Mentor and guide junior engineers in FEA best practices, modeling techniques, and interpretation of results. Present findings to stakeholders, translating technical analyses into actionable recommendations for design improvements. Stay abreast of the latest developments in FEA tools and techniques, continually enhancing the team's capabilities. Cross-Functional Integration:
Collaborate closely with R&D and manufacturing to ensure high quality thermal modules to customers

Required Qualifications:

Master's degree or Ph.D. in Mechanical Engineering, Structural Engineering, or a related field. 10+ years of experience in FEA, with a proven track record of leading complex simulation projects. Strong knowledge of material behavior, failure mechanisms, and numerical methods used in FEA. Expertise in interpreting simulation results and providing engineering insights for design optimization. Strong track record of bringing complex engineering solutions to production.

Preferred Qualifications:

Experience with CAD modeling software (e.g., Solid Works, CATIA) and its integration with FEA tools. Familiarity with advanced analysis techniques, including nonlinear analysis, dynamic analysis, and thermal analysis. Experience in the aerospace, automotive, or energy sectors. Proficiency in FEA software packages such as ANSYS, COMSOL Multiphysics. Material behavior modeling non-linear material behavior and large deformations. Develop experimental validation and extraction of fundamental material parameters required for modeling.

Strong programming skills in Python, MATLAB, or similar for automation and custom analysis tools. Solid understanding of structural mechanics, fatigue analysis, and material science principles.

Soft Skills:

Effective technical communication and ability to present to customers, executive audiences and cross-functional teams. Proven leadership in cross-functional engineering projects. Exceptional analytical and problem-solving abilities to tackle complex engineering challenges. Strong leadership skills with a focus on fostering collaboration and innovation within the team. Ability to thrive in a dynamic, fast-paced environment, adapting to changing project needs. Example Projects You Might Lead:
Architecting thermal systems for AI training clusters using liquid cooling with 100kW+ per rack. Defining inlet temperature limits and liquid temperature deltas to reduce facility cooling costs. Development of reduced-order models to optimize coldplate performance specific to customer workloads. Culture:
Frore Systems is a place where individuals can shine among their…