# Staff Thermal Engineer - Aircraft Avionics & Thermal Systems (R3930)

**Company:** [Shield AI](https://hotfix.jobs/companies/shield-ai)
**Location:** Dallas, TX, Boston, MA, San Diego, CA
**Role:** Hardware Engineering
**Salary:** $137k – $205k/yr
**Experience:** 7+ years
**Skills:** Ansys Icepak, Floefd, Star-Ccm+, Nx, Solidworks, Cfd, Heat Transfer, Fluid Mechanics, Thermal Management, Heat Pipes
**Posted:** 2025-11-14

> Leads design, analysis, and integration of thermal management systems for aircraft avionics and fluid systems using CFD tools and first-principles problem solving. Requires 7+ years experience in avionics thermal engineering and BS in Mechanical/Aerospace Engineering.

## Job Description

## Responsibilities
- Contribute to thermal analysis and design efforts for unmanned aerial vehicle avionics and thermal/fluid systems.
- Develop and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and **CFD tools** such as **FloEFD**.
- Drive test planning, instrumentation, and data analysis to correlate models with experimental results.
- Communicate technical findings clearly through executive-level briefings, design reviews, and written reports.
- Proactively identify risks, propose solutions, and influence electrical and/or PCBA design direction.

## Required Qualifications
- B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.
- Minimum 7 years of professional experience in avionics or electronics thermal engineering.
- Strong expertise in **heat transfer** (conduction, convection, radiation) and **fluid mechanics**.
- Deep understanding of active and passive cooling solutions and their integration at component and system level.
- Deep understanding of thermal management design elements including **TIMs**, **spreaders**, **heat sinks**, **vapor chambers**, **heat pipes**, and **fans**.
- Proficiency with thermal analysis and **CFD tools** (e.g., **ANSYS Icepak**, **FloEFD**, **STAR-CCM+**).
- Proficiency with **CAD design tools** such as **NX**, **SolidWorks**, or similar.
- Demonstrated experience applying first-principles reasoning to complex engineering problems.
- Strong written and verbal communication skills, with a track record of leading technical discussions and presenting to stakeholders.
- Proven ability to learn and adapt quickly to new tools, processes, and technical challenges in a fast paced, startup environment.

## Preferred Qualifications
- M.S. or Ph.D. in a relevant engineering discipline.
- Experience with high altitude aircraft avionics cooling and thermal design.
- Familiarity with aircraft integration constraints (power, weight, volume, maintainability, safety).
- Hands-on experience with thermal and fluid system testing, instrumentation, and validation.
- Knowledge of materials and manufacturing methods relevant to thermal management (**pumps**, **heat exchangers**, **composites**, etc.).
- Experience guiding trade studies, proposals, and customer interactions in aerospace or defense programs.
- Background in multi-disciplinary system integration, spanning avionics, fluid systems, and systems engineering.

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