Sr. Staff Thermal Engineer

About Marvell

Marvell’s semiconductor solutions are the essential building blocks of the data infrastructure that connects our world. Across enterprise, cloud and AI, and carrier architectures, our innovative technology is enabling new possibilities. 

At Marvell, you can affect the arc of individual lives, lift the trajectory of entire industries, and fuel the transformative potential of tomorrow. For those looking to make their mark on purposeful and enduring innovation, above and beyond fleeting trends, Marvell is a place to thrive, learn, and lead. 

Your Team, Your Impact

We are seeking a Sr. Staff Thermal Engineer to join our Advanced Technology Infrastructure team to drive the development of next‑generation cooling technologies across high‑power semiconductor test and validation platforms. This role spans early‑phase research, detailed thermal‑mechanical design, and full system‑level integration with automated handlers.

You will work at the intersection of advanced thermal, mechanical design, packaging, control systems, and automation, delivering thermal solutions that support our next wave of high‑power XPU and Silicon Photonics programs.
This position is ideal for an engineer who enjoys hands‑on development, deep modeling, and seeing concepts become validated hardware.

What You Can Expect

• Conduct feasibility modeling for next‑generation cooling technologies, including phase‑change systems, evaporative solutions, and immersion concepts.

• Evaluate early‑stage cooling architectures in collaboration with silicon, mechanical, and test engineering teams.

• Perform thermal interface material (TIM) scouting, comparative research, and preliminary characterization.

• Translate future product power‑density roadmaps into cooling performance requirements for early design phases.

• Lead end‑to‑end thermal and mechanical design of cooling assemblies, including thermal heads, manifolds, sockets, and fluid delivery structures.

• Execute full 3D thermal simulations, conjugate heat‑transfer analysis, and transient thermal modeling to predict evaporator and cold‑plate performance.

• Develop and validate TIM analysis

• Own material selection and fluid‑path design for high‑flow cooling systems, ensuring stability, reliability, and manufacturability.

• Validate integrated thermal head + socket assemblies in the lab, including structural, thermal, and reliability characterization.

• Build reliability prediction models for thermal cycling, material fatigue, creep, and long‑term system behavior.

• Develop multi‑zone thermal control concepts, including sensor strategy, PID algorithm design, loop‑tuning, and control‑firmware interaction.

• Own TIM qualification workflows including thermal resistance measurement, mechanical endurance, and process compliance.

• Script automation sequences for calibration, system setup, thermal control routines, and ATE/handler interaction.

• Work closely with handler engineering teams to ensure seamless integration of thermal heads into ATE/SLT

• Partner with silicon architects, packaging engineers, and electrical/mechanical design teams to ensure cooling compatibility and design alignment.

• Collaborate with reliability, manufacturing, and test engineering teams to define qualification plans and production‑readiness criteria.

• Interface with external vendors for thermal head manufacturing, fluid system components, TIM suppliers, and advanced materials.

What We're Looking For

• Bachelor’s degree in Mechanical Engineering, Thermal Engineering, Chemical Engineering, or related field and 5+ years of related professional experience OR Master’s degree and/or PhD in Mechanical Engineering, Thermal Engineering, Chemical Engineering, or related field (Preferred) with 3+ years of experience. 

• 3+ years of experience in thermal design, cooling systems, or mechanical systems for semiconductors, data centers, or high‑power electronics.

• Proficiency with thermal simulation tools (One or more of: Flotherm, Icepak, COMSOL, Ansys, FloEFD, or equivalent).

• Strong knowledge of heat transfer, fluid dynamics, TIMs, and mechanical stress analysis.

• Hands‑on experience validating thermal hardware in a lab environment.

• Experience with phase‑change cooling, cold‑plate design, or evaporative cooling systems

• Familiarity with high‑power device testing, thermal heads, or semiconductor handlers.

Expected Base Pay Range (USD)

118,010 - 176,800, $ per annum

The successful candidate’s starting base pay will be determined based on job-related skills, experience, qualifications, work location and market conditions. The expected base pay range for this role may be modified based on market conditions.

Additional Compensation and Benefit Elements 

Marvell is committed to providing exceptional, comprehensive benefits that support our employees at every stage - from internship to retirement and through life’s most important moments. Our offerings are built around four key pillars: financial well-being, family support, mental and physical health, and recognition. Highlights include an employee stock purchase plan with a 2-year look back, family support programs to help balance work and home life, robust mental health resources to prioritize emotional well-being, and a recognition and service awards to celebrate contributions and milestones. We look forward to sharing more with you during the interview process.

All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, sexual orientation, gender identity, disability or protected veteran status.

Any applicant who requires a reasonable accommodation during the selection process should contact Marvell HR Helpdesk at TAOps@marvell.com.

Interview Integrity 

To support fair and authentic hiring practices, candidates are not permitted to use AI tools (such as transcription apps, real-time answer generators like ChatGPT or Copilot, or automated note-taking bots) during interviews.

These tools must not be used to record, assist with, or enhance responses in any way. Our interviews are designed to evaluate your individual experience, thought process, and communication skills in real time. Use of AI tools without prior instruction from the interviewer will result in disqualification from the hiring process.

This position may require access to technology and/or software subject to U.S. export control laws and regulations, including the Export Administration Regulations (EAR). As such, applicants must be eligible to access export-controlled information as defined under applicable law. Marvell may be required to obtain export licensing approval from the U.S. Department of Commerce and/or the U.S. Department of State. Except for U.S. citizens, lawful permanent residents, or protected individuals as defined by 8 U.S.C. 1324b(a)(3), all applicants may be subject to an export license review process prior to employment.

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