Senior Staff Mechanical Systems Engineer - Spark

About the Role

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.

What You'll Be Working On

• 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.

What You'll Bring to the Team

• Bachelor's degree in Mechanical Engineering or a related field; Master's degree a plus.
• 8-12 years of mechanical engineering experience, with deep, hands-on expertise in fluid mechanics, heat transfer, structural integrity, and mechanical system dynamics.
• Direct experience designing, validating, or integrating complex liquid-cooling loops (DLC, CDUs, pumping skids, heat exchangers, or hydronic systems).
• 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.
• 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).
• Working knowledge of relevant mechanical codes and standards (e.g., ASME B31.x piping codes, ASHRAE thermal guidelines, NFPA data center cooling requirements).
• 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.

Bonus Points

• Direct experience in modular data center design.
• Background in complex adjacent industries such as aerospace, automotive, energy, or industrial process hardware.
• Experience leading design-for-manufacturability efforts with contract manufacturers.
• Familiarity with BIM workflows and full-lifecycle drawing packages (30/60/90/100%).
• Professional Engineer (PE) license.

Benefits

• Competitive compensation
• Restricted Stock Units
• Paid time off & paid holidays
• Comprehensive health, dental & vision insurance
• Employer contributions to HSA account
• Paid parental leave
• Paid life insurance, short-term and long-term disability
• Professional development & tuition reimbursement
• Mental health & wellness support
• Commuter benefits (parking & transit)
• Cell phone stipend
• 401(k) Retirement plan with company match up to 4% of salary
• Volunteer time off

Compensation Range

Compensation will be paid in the range of up to $190,000 - $215,000 + Bonus. Restricted Stock Units are included in all offers. Compensation to be determined by the applicants knowledge, education, and abilities, as well as internal equity and alignment with market data.